Abstract:
This method provides for increasing integrated circuit production of a fabrication facility comprising collecting data from a plurality of machines, calculating of the present Ratio of Running Work (RRW), comparing present RRW to optimum RRW, checking the system to determine which machines are idle, and taking steps to increase the number of running machines. Steps taken to decrease the number of idle machines include dispatching commands to a computerized dispatching system or operators. The steps of the process are repeated to further increase RRW.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to processes of manufacture of integrated circuit chips and more particularly to production control of a manufacturing process therefor. 
     2. Description of Related Art 
     As currently practiced, shift performance indicators, which are monitored by shop personnel of integrated circuit (IC) fabrication lines, are time-lag performance indicators. There are three disadvantages of time-lag performance indicators. First, no timely production line information can be provided. Second, time-lag performance indicators are unfair to each shift because of interaction between shifts brought by time-lag performance indicators. Last, utilization of machine capacity is likely to drop during the period of shift transition, where the shift transition is defined as the transition of one shift going to be off duty and another shift going to be on duty. 
     U.S. Pat. No. 5,219,765 of Yoshida et al &#34;Method for Manufacturing a Semiconductor Device Including Wafer Aging, Probe Inspection, and Feeding Back the Results of the Inspection to the Device Fabrication Process&#34; describes a method for manufacturing semiconductor devices including test from which information is fed back for fabrication process improvement. 
     U.S. Pat. No. 5,240,866 of Friedman et al &#34;Method for Characterizing Failed Circuits on Semiconductor Wafers&#34; shows a method for characterizing failed circuits on semiconductor wafers. 
     U.S. Pat. No. 5,210,041 of Kobayashi et al &#34;Process for Manufacturing Semiconductor Integrated Circuit Device&#34; shows computer control of testing/feedback to chip manufacturing process. 
     SUMMARY OF THE INVENTION 
     In accordance with this invention acceleration of integrated circuit (IC) fabrication (FAB) lines work in progress (WIP) is described and evaluated by Ratio of Running Work in Progress (RRW). In addition, RRW is a real time performance indicator of IC FAB which is related to productivity. RRW is a fair performance indicator of the management because of no interaction between shifts. The management referred to is section managers who will review performance of all shifts monthly. Productivity is one of the most important items of performance. 
     There are three improvements obtained by using RRW as a performance indicator. 
     First, production running performance can be monitored on a timely basis. 
     Second, performance of shifts can be compared fairly because no interaction is brought about between shifts. 
     Last, utilization of machine capacity can be maintained until the end of each shift. 
     In accordance with this invention, a method is provided for increasing integrated circuit production of a fabrication facility comprising 
     collecting data from a plurality of machines, supervising by calculation of present RRW, 
     comparing present RRW to optimum RRW, 
     checking the system to determine which machines are idle, and 
     taking steps increasing the number of running machines. 
     Preferably, steps taken to decrease the number of idle machines including dispatching commands to a computerized dispatching system or operators. 
     Preferably, the steps of the process are repeated to further increase RRW. 
     In accordance with another aspect of this invention, a method is provided for increasing integrated circuit production of a fabrication facility including a plurality of semiconductor processing machines comprising the program comprising: 
     (1) the supervisor program checks the RRW to determine Is RRW&lt;Target? 
     If YES, continue to (2); 
     If NO, proceed to (8) to stop the program; 
     (2) the supervisor program searches to identify a location where the RRW is less than the local target value; 
     (3) the supervisor program checks the capacity utilization to make the decision: 
     Is capacity utilization of the identified location out of control? 
     If YES, continue to (4); 
     If NO, proceed to (5); 
     (4) the supervisor program takes actions comprising 
     (a) redispatching and 
     (b) auditing idle machines, 
     (5) the supervisor program data indicating machine availability to determine whether machine availability of the identified location is out of control, If YES, continue to (6), 
     If NO, proceed to (7); 
     (6) The supervisor program takes actions including 
     (a) redispatching and 
     (b) auditing machines which are down. 
     (7) The supervisor program to determine whether there is any other location with an RRW less than the local target value, and 
     If YES, return to (2) 
     If NO, proceed to (8) to stop the program. 
     In accordance with still another aspect of this invention, a system is provided for operating an integrated circuit fabrication facility comprising 
     means for collecting data from a plurality of machines, 
     means for supervising by calculation of present RRW, 
     means for comparing present RRW to optimum RRW, 
     means for checking the system to determine which machines are idle, and 
     means for taking steps to increase the number of running machines. 
     Preferably steps are taken to decrease the number of idle machines includes dispatching commands to a computerized dispatching system or operators. 
     Preferably, the steps of the process are repeated to further increase RRW. 
     Preferably, the machines include CVD, Chemical Vapor Deposition; DIF, Diffusion; DRY Dry etching IMP, Ion implantation; PHO, Photoresist; SPU, Sputtering; WET, Wet etching; MAR,Machine Availability Ratio; processing machines. 
     Preferably, the system includes a program comprising: 
     (1) the supervisor program checks the RRW to determine Is RRW&lt;Target? 
     If YES, continue to (2); 
     If NO, proceed to (8) to stop the program; 
     (2) the supervisor program searches to identify a location where the RRW is less than the local target value; 
     (3) the supervisor program checks the capacity utilization to make the decision: 
     Is capacity utilization of the identified location out of control? 
     If YES, continue to (4); 
     If NO, proceed to (5); 
     (4) the supervisor program takes actions comprising 
     (a) redispatching and 
     (b) auditing idle machines, 
     (5) the supervisor program data indicating machine availability to determine whether machine availability of the identified location is out of control, If YES, continue to (6), If NO, proceed to (7); 
     (6) The supervisor program takes actions including 
     (a) redispatching and 
     (b) auditing machines which are down. 
     (7) The supervisor program to determine whether there is any other location with an RRW less than the local target value, and. 
     If YES, return to (2) 
     If NO, proceed to (8) to stop the program. 
     Preferably, the steps of the program are repeated to further increase RRW. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other aspects and advantages of this invention are explained and described below with reference to the accompanying drawings, in which: 
     FIG. 1 shows a process of increasing FAB productivity is illustrated in flow chart form which shows an algorithm for use on a computer connected to a FAB for optimization of the productivity of the FAB. 
     FIG. 2 shows a computer control system in accordance with this invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, a process of increasing FAB productivity is illustrated in flow chart form. The process comprises an algorithm for use on a computer connected to the FAB for optimization of the productivity of the FAB and is started as indicated by terminal block 10 in FIG. 1. 
     Step 1 
     The supervisor program as shown in decision block 11 in FIG. 1 checks Table A below. The ratio of WIP (work in progress) report is checked to determine (as indicated by decision block 11 in FIG. 1) on a FAB-wide basis: 
     Is RRW&lt;Target? 
     where RRW (Ratio of Running WIP) 
     
         Target=FAB-wide target value 
    
     If YES, continue to Step 2 in block 12. 
     If NO, proceed to step 8 in block 18. 
     For example, 0.262 is less than 0.27 so go to Step 2 in block 12. 
     Table A shows RRW FAB-wide and other data by areas listed generated by central FAB computer system showing the RRW for each area. 
     
                                           TABLE A__________________________________________________________________________RATIO OF RUNNING WIPTIME   WIP RRW CVD DIF                 DRY IMP                        PHO                           SPU                              WET__________________________________________________________________________02/22 07  30310      .209          .094              .315                 .182                     .079                        .160                           .564                              .28802/22 10  30677      .262          .156              .332                 .226                     .052                        .189                           .651                              .493TARGET 30677      .270          .200              .500                 .200                     .170                        .200                           .170                              .400__________________________________________________________________________ 
    
     Step 2 
     The supervisor program as shown in processing block 12 in FIG. 1 works to identify a location where the RRW is less than the local target value. 
     For example, location IMP (ion IMPlantation) is identified. 
     Step 3 
     The supervisor program as shown in decision block 13 in FIG. 1 checks Table B which is the capacity utilization report to make the test: 
     Is capacity utilization (of the identified location) out of a predetermined tolerable range 
     If YES, (out of a predetermined tolerable range) continue to Step 4 in block 14. 
     If NO, (in a predetermined tolerable range) proceed to step 5 in block 15. 
     For example, if capacity utilization of IMP has a value of only 0.3, that shows that there are numerous IMP machines idle and in need of an additional supply of wafers. 
     Table B shows current capacity utilization with CUR FAB-wide and the other data for FAB areas as listed. 
     
                       TABLE B______________________________________CAPACITY UTILIZATION (CUR)TIME  CUR    CVD     DIF  DRY   IMP  PHO  SPU  WET______________________________________02/22 .537   .245    .544 .754  .500 .860 .455 .2210702/22 .734   .872    .683 .750  .300 .911 .458 .51210______________________________________ 
    
     Step 4 
     The supervisor program as shown in processing block 14 in FIG. 1 takes actions including (1) redispatching and (2) auditing idle machines. Idle machines are those waiting for wafers. 
     (For example, the supervisor checks Table C comparing current dispatching status with WIP distribution and then makes a determination that it will redispatch photo machines as shown in Table D to supply more wafers to IMP machines to increase capacity utilization of IMP machines. 
     In the PHO M/C allocation column the value &#34;1&#34; for SIN-1-PHO indicates PHOTO machine numbered &#34;1&#34; is processing 
     
                       TABLE C______________________________________CURRENT PHOTO MACHINES DISPATCHING VS. WIPDISTRIBUTIONPROCESS ORDER           PHO M/COR STAGE         WIP    ALLOCATION______________________________________WAF-START        480PAD-OX-1         408SIN-1-DEP        720SIN-1-PHO        360    1SIN-1-ETCH       576N-WL-1-IMP       72WELL-OX          850SIN-1-RM         24WELL-PHO         48N-WL-2-IMP       18PWELL-PHO        24P-WL-2-IMP       24P-WL-DRIV        24WELL-DRIV        696PAD-OX-2         35SIN-2-DEP        216SIN-2-PHO        204    2SIN-2-ETCH       360N.sub.-- FLD.sub.-- IMP            24P-.sub.-- FLD.sub.-- PHO            288P-.sub.-- FLD.sub.-- IMP             0______________________________________ 
    
     wafers at SIN-1-PHO stages. The processed wafers will then come to SIN-1-ETCH stage and wait to be processed by DRY machines. 
     The value &#34;2&#34; for SIN-2-PHO indicates that PHOTO machine numbered &#34;2&#34; is processing wafers at SIN-2-PHO stage. The processed wafers will then come to SIN-1-ETCH stage and wait to be processed by DRY machines. 
     In table D below the &#34;1&#34; (for PHOTO machine numbered &#34;1&#34;) is moved to P --  -FLD --  PHO to overcome under utilization in CUR in Table B. 
     The wafers at P- --  FLD --  PHD will come to P- --  FLD --  IMP stage after they are processed by PHOTO machine numbered &#34;1&#34;, and then more IMP machines can be utilized. In the last row the &#34;0&#34; indicates under utilization (idle machines). 
     
                       TABLE D______________________________________REDISPATCHED PHOTO MACHINES VS. WIPDISTRIBUTIONPROCESS ORDER           PHO M/COR STAGE         WIP    ALLOCATION______________________________________WAF-START        480PAD-OX-1         408SIN-1-DEP        720SIN-1-PHO        360    1SIN-1-ETCH       576N-WL-1-IMP       72WELL-OX          850SIN-1-RM         24WELL-PHO         48N-WL-2-IMP       18PWELL-PHO        24P-WL-2-IMP       24P-WL-DRIV        24WELL-DRIV        696PAD-OX-2         35SIN-2-DEP        216SIN-2-PHO        204    2SIN-2-ETCH       360N.sub.-- FLD.sub.-- IMP            24P-.sub.-- FLD.sub.-- PHO            288P-.sub.-- FLD.sub.-- IMP             0     1______________________________________ 
    
     Step 5 
     The supervisor program as shown in decision block 17 in FIG. 1 checks Table E which contains data indicating Machine Availability to determine whether machine availability of the identified location is out of control. 
     If YES, (out of control) continue to Step 6 in block 16. 
     If NO, (in control) proceed to step 7 in block 17. 
     For example, only 57% of the IMP machines are available for production. The value 1.00 under WET machine listing indicates full availability. 
     
                                           TABLE E__________________________________________________________________________Machine AvailabilityTIME   CVD DIF DRY IMP PHO                     SPU WET MAR__________________________________________________________________________02/22 09:59  0.92      0.76          0.88              0.57                  0.93                     0.93                         1.00                             0.8702/22 06:57  0.89      0.76          0.90              0.86                  0.93                     0.76                         0.92                             0.85__________________________________________________________________________ 
    
     Step 6 
     The supervisor program as shown in processing block 16 in FIG. 1 takes actions including (1) redispatching and (2) auditing machines which are down. Down machines are those which are out of order. 
     For example, the supervisor sets a list of priorities for the sequence in which repairs are to be made by equipment maintenance engineers. 
     Step 7 
     The supervisor program as shown in decision block 17 in FIG. 1 checks Table A above to determine whether there is any other location with an RRW less than the local target value. 
     If YES, (out of control) return to Step 2 in block 12 
     If NO, proceed to step 8 in block 18. 
     For example, location CVD is identified as a location with an RRW less than the local target value. 
     Step 8 
     The program is ended by the supervisor program as shown by terminal block 18 in FIG. 1. 
     FIG. 2 shows a computer control system in accordance with this invention including supervisor 20 comprising a computer which can be interactively operated by an operator and alternatively can be operated independently of an operator. 
     The supervisor is connected by bus line 22 to supply data to and receive data from data tables including Run --  WIP Roll --  WIP, All --  WIP, Rolling WIP, Stopped WIP, and Idle WIP. 
     The supervisor is also connected by bus line 24 to supply data to and receive data from data table WIP. 
     The supervisor is connected by bus line 26 to supply data to machine units and receiving data from those machine units on bus line 28. The machine units include as follows: 
     CVD Chemical Vapor Deposition 
     DIF Diffusion 
     DRY Dry etching 
     IMP Ion implantation 
     PHO Photoresist (lithography) 
     SPU Sputtering 
     WET Wet etching 
     MAR Machine Availability Ratio 
     The supervisor is also connected by bus line 30 to supply data to and receive data from data table RRW. 
     The supervisor is connected by bus line 32 to supply data to and receive data from data tables including ARW, Rolling WIP, RW; Stopped WIP, SW; Idle WIP, IW; TR/dt, RTTR; Stopped Stage, SS; Idle Stage, IS; and Rolling Stage, RS. 
     Daily Turn Ratio 
     Daily Turn Ratio (DTR) is one of the most important indicators of performance for an IC fabrication line. A high value of DTR leads to a short cycle time and high productivity. DTR is usually expressed as an average number of stages through which WIP moves within one day. DTR can be interpreted as a final speed that WIP reaches at the end the day. In physics, it is well known that speed comes from acceleration. Thus, it is necessary to keep the acceleration of WIP as high as possible during a specific period to reach a high final speed at the end of the period. 
     Derivation of RRW 
     Definition of Daily Turn Ratio 
     The Daily Turn Ratio, as defined by equations (1) and (2) in Table F below, is the average number of stages through which WIP moves within one day. The final speed which WIP reaches at the end of the day is the calculation which is done. The Turn Ratio TR (which can be daily (DTR), hourly, weekly, etc.) is the speed of WIP. 
     Theory 
     Achievement of High TR 
     Achievement of High TR requires maintaining high acceleration of WIP. 
     In a given period, WIP of an IC fabrication line can be divided into three categories: 
     (1) Rolling WIP (running beginning to end, but with some stops.) 
     (2) Stopped WIP (WIP running at beginning of period, but stops during the period.) 
     (3) Idle WIP (no processing of WIP in current period.) 
     The turn ratio TR of this given period can be calculated by equation (3) in Table F. 
     Definition of Acceleration of Turn Ratio (TR) 
     Acceleration of WIP can be derived as a derivative of TR with respect to time, which is called the Real Time Turn Ratio (RTTR). In equation (4) the derivative TR/dt of equation (3) is taken, yielding the value RTTR. The second and third terms in the numerator of the equation have a derivative of &#34;0&#34; because SS k  and IS 1  are constants, and the result is shown in equation (5) in Table F. 
     Referring to equation (5), it is assumed that RS j  /dt=ARW for all RS j , J=1, . . . p, where ARW is a constant called Acceleration of Rolling WIP. Making the substitution of ARW for RS j  /dt yields equation (6) in Table F. 
     The equation (6) in Table F is equal to equation (7) because: ##EQU1## 
     Rolling WIP of a given period is equal to running WIP at the beginning of this period when the length of this period is approximately equal to zero. Thus RTTR in equation (6) in Table F is equal to equation (7). 
     Let RRW denote Ratio of Running WIP to all WIP, then the equation (9) in table F is the measure of RTTR. 
     Since ARW is an unknown constant, it is impossible to calculate RTTR from RRW. Fortunately, RRW can be used instead of RTTR to reflect acceleration of WIP at any moment because ARW is a constant. An experiment must be made to test whether there is a linear relationship between RRW and TR before acceptance of RRW as a performance indicator of a production line. 
     
                       TABLE F______________________________________ ##STR1##                      (1) ##STR2##                      (2) ##STR3##                      (3)TR/dt =                        (4) ##STR4## ##STR5##                      (5) ##STR6##                      (6) ##STR7##                      (7) ##STR8##                      (8)RTTR = RRW × ARW         (9)______________________________________ M = move n = lots in production W = work in progress S = stage RW = Rolling WIP SW = Stopped WIP IW = Idle WIP RTTR = TR/dt Run.sub.-- WIP = constant running Roll.sub.-- WIP = constant running All.sub.-- WIP = constant running 
    
     Experimental Data 
     Data of TR of every three-hours and RRW at the beginning of each three hours has been collected from July 1 to July 9 and the following model has been derived from the collected data. ##EQU2## 
     The sample correlation of the coefficient for this model is 0.96. This correlation indicates a very strong linear relationship between TR and RRW. That is, RRW is as good as TR as a performance indicator of an IC fabrication line, without consideration of other benefits brought by RRW. 
     RRW was included in a report and reviewed daily for a significant period of time. The improvements gained are shown below in Table G. Note that RRW increased 0.01 which means that a six-lot wafer out capacity increase per month occurred for a WIP=20000 pieces FAB. 
     
                       TABLE G______________________________________          Mean of                 Variance of          RRW    RRW______________________________________7/1/93-8/10/93   0.216    0.00128/11/93-9/20/93  0.226    0.0008Improvement      0.01     -0.0004Improvement in % 4.63%    -33.33%______________________________________ 
    
     SUMMARY 
     Main Points 
     Acceleration of integrated circuit (IC) fabrication (FAB) lines work in progress (WIP) can be described and evaluated by Ratio of Running Work in Progress (RRW). 
     In addition, RRW is a real time performance indicator of IC FAB which is related to turn ratio, move and throughput. 
     RRW is a fair performance indicator of the management because of no interaction between shifts. 
     Problems Solved 
     An index which can provide real time production information about acceleration of WIP and running status is provided. 
     Fluctuations in production can be avoided during shift transition. 
     While this invention has been described in terms of the above specific embodiment(s), those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims, i.e. that changes can be made in form and detail, without departing from the spirit and scope of the invention. Accordingly all such changes come within the purview of the present invention and the invention encompasses the subject matter of the claims which follow.