Patent Description:
The present disclosure relates to a substrate processing apparatus, an apparatus start-up method, a method of manufacturing a semiconductor device, and a program.

For example, when a substrate processing apparatus used in a process of manufacturing a semiconductor device is started to communicate with a management device, which manages connection of a plurality of substrate processing apparatuses, based on the SEMI standard, if the substrate processing apparatus attempts to connect to the management device that is not recognized by the substrate processing apparatus, a method of performing authentication using a password has been disclosed. The substrate processing apparatus can be managed by performing the password authentication when connecting to the management device.

When the substrate processing apparatus is connected to a new management device, there is a concern that the setting of the substrate processing apparatus may not correspond to the new management device, and further, it is conceivable that an unfamiliar and inexperienced operator may perform an erroneous operation, resulting in inefficient setup of the substrate processing apparatus.

The following document is mentioned as a relevant prior art illustration:.

Some embodiments of the present disclosure provide a technique that prevents an unfamiliar operator from performing an erroneous operation when a substrate processing apparatus is connected to a new management device, to enable efficient setup of the substrate processing apparatus.

According to one embodiment of the present disclosure, there is provided a technique that includes a process chamber configured to be capable of processing a substrate; a main controller configured to be capable of controlling the processing of the substrate; a storage configured to be capable of storing start-up condition execution status information used to determine whether or not a start-up condition is executed when the main controller is started, start-up condition management information for managing the start-up condition, and a state of the start-up condition management information; and a start-up condition controller configured to be capable of validating the start-up condition execution status information when the start-up condition management information satisfies a predetermined condition.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present disclosure.

Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, systems, and components have not been described in detail so as not to unnecessarily obscure aspects of the various embodiments.

Hereinafter, embodiments of the present disclosure will be described.

First, a first embodiment of the present disclosure will be described with reference to the drawings.

The configuration of a system including a substrate processing apparatus according to embodiments of the present disclosure will be described with reference to <FIG> is a schematic configuration diagram of a system including a substrate processing apparatus according to embodiments of the present disclosure.

As shown in <FIG>, the system includes at least one substrate processing apparatus <NUM> and a management device <NUM> connected to the substrate processing apparatus <NUM> to be capable of controlling a substrate of the substrate processing apparatus. The substrate processing apparatus <NUM> is configured to execute a processing process based on a recipe in which processing procedures and process conditions are defined. The substrate processing apparatus <NUM> and the management device <NUM> are connected by a network <NUM> such as a local area network (LAN) or a wide area network (WAN).

Subsequently, the configuration of the substrate processing apparatus <NUM> according to the embodiments of the present disclosure will be described with reference to <FIG> and <FIG>. <FIG> is a perspective view of the substrate processing apparatus according to the embodiments of the present disclosure. <FIG> is a side perspective view of the substrate processing apparatus according to the embodiments of the present disclosure. The substrate processing apparatus <NUM> according to the present embodiment is configured as a vertical apparatus that performs an oxidation process, a diffusion process, a CVD process, and the like on a substrate such as a wafer.

As shown in <FIG> and <FIG>, the substrate processing apparatus <NUM> according to the present embodiment includes a housing <NUM> configured as a pressure-resistant container. A front maintenance opening <NUM> as an opening provided for maintenance is opened in the forward front portion of a front wall 111a of the housing <NUM>. The front maintenance opening <NUM> is provided with a pair of front maintenance doors <NUM> as an entrance mechanism for opening/closing the front maintenance opening <NUM>. A pod (substrate container) <NUM> containing a wafer (substrate) <NUM> of silicon or the like is used as a carrier for transferring the wafer <NUM> into/out of the housing <NUM>.

A pod loading/unloading port (substrate container loading/unloading port) <NUM> is opened in the front wall 111a of the housing <NUM> so as to communicate the inside and outside of the housing <NUM>. The pod loading/unloading port <NUM> is opened/closed by a front shutter (substrate container loading/unloading port opening/closing mechanism) <NUM>. A load port (substrate container delivery table) <NUM> is installed as a mounting table on the forward front side of the pod loading/unloading port <NUM>. A pod <NUM> is configured to be mounted and aligned on the load port <NUM>. The pod <NUM> is configured to be transferred onto the load port <NUM> by an in-process transfer device (not shown) such as an OHT (Overhead Hoist Transport).

A rotary pod shelf (substrate container mounting shelf) <NUM> is installed in the upper portion of the housing <NUM> at substantially the central portion in the front-rear direction. A plurality of pods <NUM> is configured to be stored on the rotary pod shelf <NUM>. The rotary pod shelf <NUM> has a post <NUM> that is vertically erected and intermittently rotated in a horizontal plane, and a plurality of shelf boards (substrate container mounting tables) <NUM> that is radially supported at respective positions of the upper, middle, and lower stages of the post <NUM>. The plurality of shelf boards <NUM> is configured to mount and hold the plurality of pods <NUM>, respectively.

A pod transfer device (substrate container transfer device) <NUM> is installed between the load port <NUM> and the rotary pod shelf <NUM> in the housing <NUM>. The pod transfer device <NUM> includes a pod elevator (substrate container elevating mechanism) 118a capable of moving up and down while holding the pod <NUM>, and a pod transfer mechanism (substrate container transfer mechanism) 118b as a transfer mechanism. The pod transfer device <NUM> is configured to transfer the pod <NUM> between the load port <NUM>, the rotary pod shelf <NUM>, and a pod opener (substrate container lid opening/closing mechanism) <NUM> by continuous operation of the pod elevator 118a and the pod transfer mechanism 118b.

A sub-housing <NUM> is provided in the lower portion of the housing <NUM> from substantially the central portion in the front-rear direction of the housing <NUM> to the rear end thereof. A pair of wafer loading/unloading ports (substrate loading/unloading ports) <NUM> for transferring the wafer <NUM> into/out of the sub-housing <NUM> is arranged vertically in two stages of an upper stage and a lower stage on a front wall 119a of the sub-housing <NUM>. The pod opener <NUM> is installed at each of the wafer loading/unloading ports <NUM> on the upper and lower stages.

Each pod opener <NUM> includes a pair of mounting tables <NUM> on which the pod <NUM> is mounted, and a cap attaching/detaching mechanism (lid attaching/detaching mechanism) <NUM> for attaching/detaching a cap (lid) of the pod <NUM>. The pod opener <NUM> is configured to open/close a wafer entrance of the pod <NUM> by attaching/detaching the cap of the pod <NUM> mounted on the mounting table <NUM> by the cap attaching/detaching mechanism <NUM>.

A transfer chamber <NUM> that is fluidly isolated from a space in which the pod transfer device <NUM>, the rotary pod shelf <NUM>, and the like are installed is constituted in the sub-housing <NUM>. A wafer transfer mechanism (substrate transfer mechanism) <NUM> is installed in the front region of the transfer chamber <NUM>. The wafer transfer mechanism <NUM> is composed of a wafer transfer device (substrate transfer device) 125a that can rotate or linearly move the wafer <NUM> in the horizontal direction, and a wafer transfer device elevator (substrate transfer device elevating mechanism) 125b for raising and lowering the wafer transfer device 125a. As shown in <FIG>, the wafer transfer device elevator 125b is installed between the right end portion of the front region of the transfer chamber <NUM> of the sub-housing <NUM> and the right end portion of the housing <NUM>. The wafer transfer device 125a includes tweezers (substrate holder) 125c as a mounting portion for the wafer <NUM>. By continuous operation of the wafer transfer device elevator 125b and the wafer transfer device 125a, the wafer <NUM> can be loaded (charged) and unloaded (discharged) into and from a boat (substrate holder) <NUM>.

A standby part <NUM> for accommodating the boat <NUM> to be put on standby is configured in the rear region of the transfer chamber <NUM>. A process furnace <NUM> is installed above the standby part <NUM>. The lower end portion of the process furnace <NUM> is configured to be opened/closed by a furnace opening shutter (furnace opening/closing mechanism) <NUM>.

As shown in <FIG>, a boat elevator (substrate holder elevating mechanism) <NUM> for raising and lowering the boat <NUM> is installed between the right end portion of the standby part <NUM> of the sub-housing <NUM> and the right end portion of the housing <NUM>. An arm <NUM> as a connecting member is connected to an elevating stand of the boat elevator <NUM>. A seal cap <NUM> as a lid is horizontally installed on the arm <NUM>. The seal cap <NUM> is configured to vertically support the boat <NUM> so as to be capable of sealing the lower end portion of the process furnace <NUM>.

A substrate transfer system according to the present embodiment mainly includes the rotary pod shelf <NUM>, the boat elevator <NUM>, the pod transfer device (substrate container transfer device) <NUM>, the wafer transfer mechanism (substrate transfer mechanism) <NUM>, the boat <NUM>, and a rotation mechanism <NUM> which will be described later. The rotary pod shelf <NUM>, boat elevator <NUM>, pod transfer device (substrate container transfer device) <NUM>, wafer transfer mechanism (substrate transfer mechanism) <NUM>, boat <NUM>, and rotation mechanism <NUM> are electrically connected to a transfer controller <NUM> as a sub-controller to be described later.

The boat <NUM> includes a plurality of holding members. The boat <NUM> is configured to hold a plurality of wafers <NUM> (for example, about <NUM> to <NUM> wafers) horizontally, which are arranged in the vertical direction with their centers aligned with one another.

As shown in <FIG>, a clean unit <NUM> is installed in the left end portion of the transfer chamber <NUM> opposite to the wafer transfer device elevator 125b side and the boat elevator <NUM> side. The clean unit <NUM> is composed of a supply fan and a dust-proof filter so as to supply clean air <NUM> which is a cleaned atmosphere or an inert gas. A notch alignment device (not shown) as a substrate matching device for matching the position of the wafer in the circumferential direction is installed between the wafer transfer device 125a and the clean unit <NUM>.

The clean air <NUM> blown out from the clean unit <NUM> circulates around the notch alignment device (not shown), the wafer transfer device 125a, and the boat <NUM> in the standby part <NUM>, and then is sucked by a duct (not shown) and exhausted to the outside of the housing <NUM> or is circulated to the primary side (supply side) which is the suction side of the clean unit <NUM> and then blown out again into the transfer chamber <NUM> by the clean unit <NUM>.

A plurality of apparatus covers (not shown) as a mechanism for entering the substrate processing apparatus <NUM> are attached to the outer periphery of the housing <NUM> and the sub-housing <NUM>. These apparatus covers are configured to be separated during maintenance work so that a maintenance personnel can enter the substrate processing apparatus <NUM>. A door switch <NUM> as an entrance sensor is installed at the end portions of the housing <NUM> and the sub-housing <NUM> facing these apparatus covers. A door switch <NUM> as an entrance sensor is also installed at the end portion of the housing <NUM> facing the front maintenance door <NUM>. A substrate detection sensor <NUM> for detecting the mount of the pod <NUM> is also installed on the load port <NUM>. The switches and sensors <NUM> such as the door switch <NUM> and substrate detection sensor <NUM> are electrically connected to a substrate processing apparatus controller <NUM> which will be described later.

Next, the operation of the substrate processing apparatus <NUM> according to the present embodiment will be described with reference to <FIG> and <FIG>.

As shown in <FIG> and <FIG>, when the pod <NUM> is supplied to the load port <NUM> by the in-process transfer device (not shown), the pod <NUM> is detected by the substrate detection sensor <NUM> and the pod loading/unloading port <NUM> is opened by the front shutter <NUM>. Then, the pod <NUM> on the load port <NUM> is loaded into the housing <NUM> from the pod loading/unloading port <NUM> by the pod transfer device <NUM>.

The pod <NUM> loaded into the housing <NUM> is automatically transferred by the pod transfer device <NUM> onto the shelf board <NUM> of the rotary pod shelf <NUM> and is temporarily stored in the shelf board <NUM>. Thereafter, the pod <NUM> is transferred from the shelf board <NUM> onto the mounting table <NUM> of one pod opener <NUM>. The pod <NUM> loaded into the housing <NUM> may be directly transferred onto the mounting table <NUM> of the pod opener <NUM> by the pod transfer device <NUM>. At this time, the wafer loading/unloading port <NUM> of the pod opener <NUM> is closed by the cap attaching/detaching mechanism <NUM>, and the clean air <NUM> is circulated and filled in the transfer chamber <NUM>. For example, a nitrogen gas as the clean air <NUM> is filled in the transfer chamber <NUM>, so that an oxygen concentration is set to <NUM> ppm or less, which is much lower than the oxygen concentration of the interior (air atmosphere) of the housing <NUM>.

The opening side end face of the pod <NUM> mounted on the mounting table <NUM> is pressed against the opening edge of the wafer loading/unloading port <NUM> on the front wall 119a of the sub-housing <NUM>, and the cap of the pod <NUM> is separated by the cap attaching/detaching mechanism <NUM> and the wafer entrance is opened. After that, the wafer <NUM> is picked up from the pod <NUM> by the tweezers 125c of the wafer transfer device 125a through the wafer entrance, is aligned in orientation by the notch alignment device, is loaded into the standby part <NUM> at the rear of the transfer chamber <NUM>, and then is charged into the boat <NUM>. The wafer transfer device 125a that has charged the wafer <NUM> into the boat <NUM> returns to the pod <NUM>, and charges the next wafer <NUM> into the boat <NUM>.

During the charging work of the wafer <NUM> into the boat <NUM> by the wafer transfer mechanism <NUM> in one (upper or lower) pod opener <NUM>, another pod <NUM> is transferred by the pod transfer device <NUM> from the rotary pod shelf <NUM> to the mounting table <NUM> of the other (lower or upper) pod opener <NUM>, so that the opening work of the pod <NUM> by the pod opener <NUM> is simultaneously performed.

When a predetermined number of wafers <NUM> are charged into the boat <NUM>, the lower end portion of the process furnace <NUM> closed by the furnace opening shutter <NUM> is opened by the furnace opening shutter <NUM>. Subsequently, the boat <NUM> holding the group of wafers <NUM> is loaded into the process furnace <NUM> by raising the seal cap <NUM> by the boat elevator <NUM>.

After the boat loading, an arbitrary process is performed on the wafers <NUM> in the process furnace <NUM>. After the process, according to substantially the reverse procedure of the above-described procedure, except for a wafer alignment step in the notch alignment device <NUM>, the boat <NUM> storing the processed wafers <NUM> is unloaded from the process chamber <NUM>, and the pod <NUM> storing the processed wafers <NUM> is unloaded out of the housing <NUM>.

Subsequently, the configuration of the process furnace <NUM> according to the present embodiment will be described with reference to <FIG> is a longitudinal sectional view of the process furnace <NUM> of the substrate processing apparatus <NUM> according to embodiments of the present disclosure.

As shown in <FIG>, the process furnace <NUM> includes a process tube <NUM> as a reaction tube. The process tube <NUM> includes an inner tube <NUM> as an internal reaction tube and an outer tube <NUM> as an external reaction tube installed outside the inner tube <NUM>. The inner tube <NUM> is made of a heat resistant material such as quartz (SiO<NUM>) or silicon carbide (SiC). The inner tube <NUM> is formed in a cylindrical shape with its upper and lower ends opened. A process chamber <NUM> for processing a wafer <NUM> as a substrate is formed in a cylindrical hollow portion of the inner tube <NUM>. The interior of the process chamber <NUM> is configured to be capable of accommodating a boat <NUM> which will be described later. The outer tube <NUM> is installed to be concentric with the inner tube <NUM>. The outer tube <NUM> has an inner diameter larger than the outer diameter of the inner tube <NUM> and is formed in a cylindrical shape with its upper end closed and its lower end opened. The outer tube <NUM> is made of a heat resistant material such as quartz or silicon carbide.

A heater <NUM> as a heating mechanism is installed outside the process tube <NUM> so as to surround a sidewall surface of the process tube <NUM>. The heater <NUM> is configured in a cylindrical shape. The heater <NUM> is supported by a heater base <NUM> as a support plate so as to be installed vertically.

A manifold <NUM> is arranged below the outer tube <NUM> so as to be concentric with the outer tube <NUM>. The manifold <NUM> is made of, for example, stainless steel. The manifold <NUM> is formed in a cylindrical shape with its upper and lower ends opened. The manifold <NUM> engages with the lower end portion of the inner tube <NUM> and the lower end portion of the outer tube <NUM>, respectively. The manifold <NUM> is installed to support the lower end portion of the inner tube <NUM> and the lower end portion of the outer tube <NUM>. An O-ring 220a as a seal member is installed between the manifold <NUM> and the outer tube <NUM>. As the manifold <NUM> is supported by the heater base <NUM>, the process tube <NUM> is vertically installed. A reaction container is formed by the process tube <NUM> and the manifold <NUM>.

A process gas nozzle 230a and a purge gas nozzle 230b as gas introduction parts are connected to the seal cap <NUM> to be described later so as to communicate with the interior of the process chamber <NUM>. A process gas supply pipe 232a is connected to the process gas nozzle 230a. A process gas supply source (not shown) and the like are connected to the upstream side of the process gas supply pipe 232a (the side opposite to the connection side with the process gas nozzle 230a) via a mass flow controller (MFC) 241a as a gas flow controller. A purge gas supply pipe 232b is connected to the purge gas nozzle 230b. A purge gas supply source (not shown) and the like are connected to the upstream side of the purge gas supply pipe 232b (the side opposite to the connection side with the purge gas nozzle 230b) via a mass flow controller (MFC) 241b as a gas flow controller.

A process gas supply system according to the present embodiment mainly includes the process gas supply source (not shown), the MFC 241a, the process gas supply pipe 232a, and the process gas nozzle 230a. A purge gas supply system according to the present embodiment mainly includes the purge gas supply source (not shown), the MFC 241b, the purge gas supply pipe 232b, and the purge gas nozzle 230b. A gas supply system according to the present embodiment mainly includes the process gas supply system and the purge gas supply system. A gas supply controller <NUM> as a sub-controller, which will be described later, is electrically connected to the MFCs 241a and 241b.

In the manifold <NUM>, an exhaust pipe <NUM> for exhausting the internal atmosphere of the process chamber <NUM> is installed. The exhaust pipe <NUM> is arranged at the lower end portion of a tubular space <NUM> formed by a gap between the inner tube <NUM> and the outer tube <NUM>. The exhaust pipe <NUM> communicates with the tubular space <NUM>. A pressure sensor <NUM> as a pressure detector, a pressure regulator <NUM> configured as, for example, an auto pressure controller (APC), and a vacuum exhaust device <NUM> such as a vacuum pump are connected to the downstream side of the exhaust pipe <NUM> (the side opposite to the connection side with the manifold <NUM>) sequentially from the upstream side. A gas exhaust system according to the present embodiment mainly includes the exhaust pipe <NUM>, the pressure sensor <NUM>, and the pressure regulator <NUM>. A pressure controller <NUM> as a sub-controller, which will be described later, is electrically connected to the pressure regulator <NUM> and the pressure sensor <NUM>. The vacuum exhaust device <NUM> may be included in the gas exhaust system.

The seal cap <NUM> as a furnace opening cover capable of hermetically closing the lower end opening of the manifold <NUM> is installed below the manifold <NUM>. The seal cap <NUM> abuts against the lower end of the manifold <NUM> from below in the vertical direction. The seal cap <NUM> is made of, for example, metal such as stainless steel. The seal cap <NUM> is formed in a disc shape. An O-ring 220b is installed on the upper surface of the seal cap <NUM> as a seal member that contacts the lower end of the manifold <NUM>.

The rotation mechanism <NUM> for rotating the boat is installed near the central portion of the seal cap <NUM> and on the side opposite to the process chamber <NUM>. A rotary shaft <NUM> of the rotation mechanism <NUM> penetrates the seal cap <NUM> and supports the boat <NUM> from below. The rotation mechanism <NUM> is configured to be capable of rotating the wafer <NUM> by rotating the boat <NUM>.

The seal cap <NUM> is configured to be vertically raised and lowered by the boat elevator <NUM> as a substrate holder elevating mechanism installed vertically outside the process tube <NUM>. The boat <NUM> is configured to be capable of being transferred into/out of the process chamber <NUM> by raising and lowering the seal cap <NUM>. The rotation mechanism <NUM> and the boat elevator <NUM> are electrically connected to the transfer controller <NUM> as a sub-controller which will be described later.

As described above, the boat <NUM> as the substrate holder is configured to align and hold a plurality of wafers <NUM> in a horizontal posture and in multiple stages with their centers aligned with one another. The boat <NUM> is made of, for example, a heat resistant material such as quartz or silicon carbide. A plurality of heat insulating plates <NUM> as heat insulating members is arranged in a horizontal posture and in multiple stages in the lower portion of the boat <NUM>. The heat insulating plates <NUM> are formed in a disc shape. The heat insulating plates <NUM> are made of, for example, a heat resistant material such as quartz or silicon carbide. The heat insulating plates <NUM> are configured to make it difficult for heat from the heater <NUM> to be transferred to the manifold <NUM> side.

A temperature sensor <NUM> as a temperature detector is installed in the process tube <NUM>. A heating mechanism according to the present embodiment mainly includes the heater <NUM> and the temperature sensor <NUM>. The heater <NUM> and the temperature sensor <NUM> are electrically connected to a temperature controller <NUM> as a sub-controller which will be described later.

A substrate processing system according to the present embodiment mainly includes the gas exhaust system, the gas supply system, and the heating mechanism.

Subsequently, as a process of manufacturing a semiconductor device, a method of forming a thin film on a wafer <NUM> by a CVD method using the process furnace <NUM> having the above configuration will be described with reference to <FIG>. In the following description, the operation of each part constituting the substrate processing apparatus <NUM> is controlled by the substrate processing apparatus controller <NUM>.

When a plurality of wafers <NUM> is charged into the boat <NUM> (wafer charge), as shown in <FIG>, the boat <NUM> holding the plurality of wafers <NUM> is lifted by the boat elevator <NUM> and is loaded into the process chamber <NUM> (boat loading). In this state, the seal cap <NUM> seals the lower end of the manifold <NUM> via the O-ring 220b.

The interior of the process chamber <NUM> is vacuum-exhausted by the vacuum exhaust device <NUM> so as to have a desired pressure (degree of vacuum). At this time, based on a pressure value measured by the pressure sensor <NUM>, the degree of opening of the valve of the pressure regulator <NUM> is feedback-controlled. Further, the interior of the process chamber <NUM> is heated by the heater <NUM> so as to reach a desired temperature. At this time, based on a temperature value detected by the temperature sensor <NUM>, the amount of electric power supplied to the heater <NUM> is feedback-controlled. Subsequently, the boat <NUM> and the wafers <NUM> are rotated by the rotation mechanism <NUM>.

Next, a process gas, which is supplied from the process gas supply source and controlled by the MFC 241a to have a desired flow rate, flows through the process gas supply pipe 232a and is introduced into the process chamber <NUM> from the nozzle 230a. The introduced process gas rises in the process chamber <NUM>, flows out into the tubular space <NUM> through the upper end opening of the inner tube <NUM>, and is exhausted through the exhaust pipe <NUM>. As the gas passes through the process chamber <NUM>, it contacts the surfaces of the wafers <NUM>, and at this time, a thin film is deposited on the surfaces of the wafers <NUM> by a thermal CVD reaction.

After a preset processing time has passed, a purge gas, which is supplied from the purge gas supply source and controlled by the MFC 241b to have a desired flow rate, is supplied into the process chamber <NUM>, and the interior of the process chamber <NUM> is substituted with an inert gas and the internal pressure of the process chamber <NUM> is returned to the normal pressure.

After that, the seal cap <NUM> is lowered by the boat elevator <NUM>, and the lower end of the manifold <NUM> is opened and the boat <NUM> holding the processed wafers <NUM> is unloaded from the lower end of the manifold <NUM> to the outside of the process tube <NUM> (boat unloading). Thereafter, the processed wafers <NUM> are taken out from the boat <NUM> and are stored in the pod <NUM> (wafer discharge).

A controller (hereinafter also referred to as a main controller) <NUM> as the substrate processing apparatus controller will be described below with reference to <FIG>.

The main controller <NUM> mainly includes a central processing unit (CPU) <NUM> as an arithmetic controller, a process control part <NUM> for controlling a process controller, a transfer control part <NUM> for controlling the transfer controller <NUM>, a transmitter/receiver <NUM> for communicating with the management device <NUM>, a storage <NUM> composed of a memory such as a RAM and a ROM, a HDD, and the like, an input part <NUM> such as a mouse or a keyboard, a display <NUM> such as a monitor, a start-up condition controller <NUM> for controlling start-up condition execution status information <NUM> used to determine whether or not the start-up condition is executed when the main controller <NUM> is started up, a password calculator <NUM> for calculating a password when the start-up condition controller <NUM> determines that password authentication is required, and a counter <NUM> for counting the number of times of operation stop of the main controller <NUM> and the number of mismatches when entering a password. The CPU <NUM>, the storage <NUM>, the input part <NUM>, the display <NUM>, the start-up condition controller <NUM>, the password calculator <NUM>, the counter <NUM>, and a clock function (not shown) constitute an operation part capable of setting data.

The CPU <NUM> constitutes a core of the main controller <NUM>, executes a control program stored in a ROM (not shown), and executes recipes (for example, a process recipe as a substrate process recipe) stored in the storage <NUM>, which also constitutes a recipe storage <NUM>, according to instructions from the display <NUM>. The ROM is composed of an EEPROM, a flash memory, a hard disk, etc., and is a recording medium for storing an operation program for the CPU <NUM>, and the like. The memory (RAM) functions as a work area (temporary storage part) for the CPU <NUM>, and the like.

Here, the substrate process recipe is a recipe in which process conditions, processing procedures, and the like for processing the wafer <NUM> are defined. In a recipe file, setting values (control values), transmission timings, etc. to be transmitted to the transfer controller <NUM>, the temperature controller <NUM>, the pressure controller <NUM>, the gas supply controller <NUM>, etc. are set for each step of substrate processing.

Further, the main controller <NUM> according to the embodiment of the present disclosure can be realized using a normal computer system without using a dedicated system. For example, by installing various programs including a control program for executing the above-described process in a general-purpose computer from an external recording medium (flexible disk, CD-ROM, USB, external HDD, etc.) storing the various programs, the main controller <NUM> that executes the above-described process can be configured.

A means for supplying these various programs is arbitrary. In addition to the means of capable of supplying the various programs via a predetermined recording medium as described above, the various programs may be supplied via, for example, a communication line, a communication network, a communication system, or the like. In this case, for example, a corresponding program may be disclosed on a bulletin board of a communication network, and be provided with it superimposed on a carrier wave via a network. By activating the program provided in this way and executing it in the same manner as other application programs under the control of an OS, the above-described process can be executed.

The process control part <NUM> has a function of controlling the internal temperature and internal pressure of the process furnace <NUM>, the flow rate of a process gas introduced into the process furnace <NUM>, etc. so that the wafer <NUM> loaded in the process furnace <NUM> are subjected to a predetermined process.

The transfer control part <NUM> has a function of controlling the driving of the transfer mechanisms such as the pod transfer device <NUM>, the wafer transfer mechanism <NUM>, the boat elevator <NUM>, and the like via drive motors (not shown).

The storage <NUM> has a data storage area <NUM> in which various data and the like are stored, and a program storage area <NUM> in which various programs are stored.

The data storage area <NUM> stores various parameters related to the recipe file. In addition, the data storage area <NUM> stores information of a delivery position on load port <NUM> as an I/O stage when the pod <NUM> is loaded into the housing <NUM> and when the pod <NUM> is unloaded out of the housing <NUM>, information of the order of operation when the pod transfer device <NUM> as a carrier loader is moved to the delivery position, information of the order of operation when the carrier loader <NUM> is moved from the delivery position, etc. Further, the data storage area <NUM> stores carrier information including at least a carrier ID that identifies each pod <NUM>, and type information of the wafer <NUM> in the pod <NUM>.

Further, in the present embodiment, the data storage area <NUM> stores threshold information <NUM> of the elapsed time (also referred to as first threshold information), threshold information <NUM> of the number of password mismatches (also referred to as second threshold information), and threshold information <NUM> of the number of times of operation stop of the main controller <NUM> (also referred to as third threshold information), which is one of the setting conditions of the start-up condition execution status information <NUM>.

Furthermore, in the present embodiment, the data storage area <NUM> stores start-up condition management information <NUM> as information related to the start-up of the main controller <NUM>. The start-up condition management information <NUM> stores a management device connection state <NUM> that stores the state of connection with the management device <NUM>, an operation stop count <NUM> that records the number of times of operation stop of the main controller <NUM>, the start-up condition execution status information <NUM> that is used as authentication information when the main controller <NUM> is started, and operation stop information <NUM> that has the date and time when the operation of the previous main controller <NUM> is stopped.

Furthermore, in the present embodiment, the storage <NUM> can temporarily store the calculated password calculated by the password calculator, and the number of password mismatches that counts the number of mismatches of an input password when password authentication is required when the main controller <NUM> is started. The counter counts the number of mismatches of the input password.

The program storage area <NUM> stores, in addition to the above-mentioned substrate process recipe and the like, various programs necessary for loading and unloading a cassette <NUM>, recipes for cleaning the interior of the furnace without substrates, and the like. Further, for example, the program storage area <NUM> is configured to be capable of storing a software program for performing authentication determination when the main controller is started, which will be described later. In addition, the program storage area <NUM> is configured to be capable of storing a software program for calculating a password when authentication of the password is required when the main controller is started, which will be described later.

The display <NUM> of the main controller <NUM> is provided with a touch panel. The touch panel is configured to display an operation screen for receiving an input of operation commands to the above-described substrate transfer system and substrate processing system. This operation screen includes various display fields and operation buttons for checking the states of the substrate transfer system and the substrate processing system and inputting operation instructions to the substrate transfer system and the substrate processing system. The operation part may have a configuration including at least the display <NUM> and the input part <NUM>, like an operation terminal (terminal device) such as a personal computer or a mobile device.

The transfer controller <NUM> is configured to control the transfer operations of the rotary pod shelf <NUM>, the boat elevator <NUM>, the pod transfer device (substrate container transfer device) <NUM>, the wafer transfer mechanism (substrate transfer mechanism) <NUM>, the boat <NUM>, and the rotation mechanism <NUM>, which constitute the substrate transfer system. Further, although not shown, sensors are built in the rotary pod shelf <NUM>, the boat elevator <NUM>, the pod transfer device (substrate container transfer device) <NUM>, the wafer transfer mechanism (substrate transfer mechanism) <NUM>, the boat <NUM>, and the rotation mechanism <NUM>, respectively, which constitute the substrate transfer system. The transfer controller <NUM> is configured to notify the main controller <NUM> when each of these sensors indicates a predetermined value or an abnormal value.

Based on a pressure value detected by the pressure sensor <NUM>, the pressure controller <NUM> is configured to control the pressure regulator <NUM> so that the internal pressure of the process chamber <NUM> reaches a desired pressure at a desired timing, and to notify the main controller <NUM> when the pressure sensor <NUM> indicates a predetermined value or an abnormal value.

The gas supply controller <NUM> is configured to control the supply and stop of gases from the process gas supply pipe 232a and the purge gas supply pipe 232b by opening/closing gas valves (not shown). Further, the gas supply controller <NUM> is configured to control the MFCs 241a and 241b so that the flow rate of a gas supplied into the process chamber <NUM> reaches a desired flow rate at a desired timing. The gas supply controller <NUM> is configured to notify the main controller <NUM> when a gas valve (not shown) or a sensor (not shown) installed in the MFCs 241a and 241b indicates a predetermined value or an abnormal value.

Next, an embodiment related to the determination of the start-up condition of the main controller will be described with reference to <FIG>, <FIG>, <FIG>, <FIG>, and the like. In addition, an embodiment related to the operation stop of the main controller <NUM> will be described with reference to <FIG> and the like. Further, an embodiment related to the setting of the start-up condition execution status information <NUM> will be described with reference to <FIG>, <FIG>, <FIG>, and the like.

<FIG> shows the operation of executing the start-up condition when the main controller is started. This operation includes, for example, a start-up condition execution confirmation step (S100) of determining whether or not execution of the start-up condition is required, an elapsed time confirmation step (S <NUM>) of confirming the elapsed time from the most recent operation stop time of the main controller <NUM> when it is determined that the execution of the start-up condition is required in the start-up condition execution confirmation step (S100), and a password confirmation step (S120) that is executed when authentication by password input is required.

Next, the start-up condition execution confirmation step S100 will be described. In the start-up condition execution confirmation step S100, when the main controller <NUM> is started, the CPU <NUM> instructs the start-up condition controller <NUM> to confirm the start-up condition execution. The start-up condition controller <NUM> performs the start-up condition confirmation operation shown in <FIG> according to the instruction of the start-up condition execution confirmation from the CPU <NUM>. The start-up condition controller <NUM> acquires the setting state of the start-up condition execution status information <NUM> stored in the data storage area <NUM> of the storage <NUM> (S1000) and confirms the acquired start-up condition execution status information <NUM> (S1010). If the start-up condition execution status information <NUM> is set to be valid, it is confirmed that authentication is required (S <NUM>), and if the start-up condition execution status information <NUM> is set to be invalid, it is confirmed that execution of the start-up condition is not required (S1030), and the result confirmed as a start-up condition confirmation result is returned to the CPU <NUM>.

When the CPU <NUM> determines that the execution of the start-up condition is required based on the confirmed result from the start-up condition controller <NUM>, the CPU <NUM> instructs the start-up condition controller <NUM> to confirm the elapsed time.

If the CPU <NUM> determines that the execution of the start-up condition is not required based on the start-up condition confirmation result from the start-up condition controller <NUM>, the main controller <NUM> may be started up without performing the following elapsed time confirmation step (S110) and password confirmation step (S120).

Next, the elapsed time confirmation step S110 will be described. The start-up condition controller <NUM> performs the elapsed time confirmation operation shown in <FIG> according to an instruction of the elapsed time confirmation from the CPU <NUM>. The start-up condition controller <NUM> acquires the operation stop information <NUM> stored in the data storage area <NUM> of the storage <NUM> (S1100), acquires start-up information of the main controller <NUM> from the clock function of the main controller (S1110), and calculates the elapsed time from the previous operation stop from the operation stop information <NUM> and the start-up information (S1120).

Next, the start-up condition controller <NUM> acquires a first threshold value stored in a parameter storage <NUM> of the storage <NUM> and compares it with the elapsed time calculated in the step S1120 (S1130). As a result of the comparison in the step S1130, if the elapsed time calculated in the step S1120 exceeds the first threshold value <NUM>, it is confirmed that password authentication is required (S1140). On the other hand, if the elapsed time calculated in the step S1120 is equal to the first threshold value <NUM> or is smaller than the first threshold value <NUM>, it is confirmed that password authentication is not required (S1150), and the result confirmed as an elapsed time confirmation result is returned to the CPU <NUM>.

When the CPU <NUM> determines that the password authentication is required based on the elapsed time confirmation result from the start-up condition controller <NUM>, the CPU <NUM> instructs the start-up condition controller <NUM> to confirm the password.

When the CPU <NUM> determines that the password authentication is not required based on the confirmed result from the start-up condition controller <NUM>, the main controller <NUM> may be started up without performing the following password confirmation step (S120).

When the CPU <NUM> determines that the password authentication is required based on the elapsed time confirmation result from the start-up condition controller <NUM>, the CPU <NUM> instructs the password calculator <NUM> to calculate the password. Upon receiving the password calculation instruction from the CPU <NUM>, the password calculator <NUM> calculates a password that is valid only for the day, and stores it in the data storage area of the storage <NUM>, as a calculated password <NUM>.

The calculated password <NUM> is valid only during the password confirmation step (S120) and may be deleted from the data storage area <NUM> of the storage <NUM> when the password confirmation step (S120) is completed.

When the CPU <NUM> determines that the password authentication is required based on the elapsed time confirmation result from the start-up condition controller <NUM>, the CPU <NUM> instructs the input part <NUM> to input a password. In addition, the CPU <NUM> instructs the display <NUM> to display a password request. Upon receiving input of the password, the input part <NUM> returns the input password to the CPU <NUM> as an instruction response to the password input request. The CPU <NUM> passes the input password received from the input part <NUM> to the start-up condition controller <NUM>.

Next, the password confirmation step S120 will be described. The start-up condition controller <NUM> performs the password confirmation operation shown in <FIG> according to an instruction of the password confirmation from the CPU <NUM>. Upon acquiring the input password from the CPU <NUM> (S1200), the start-up condition controller <NUM> acquires the calculated password <NUM> stored in the data storage area <NUM> of the storage <NUM> (S1210) and compares the input password with the calculated password <NUM> (S1220).

Next, as the result of the step S1220, if the start-up condition controller <NUM> determines that there is a match, the password authentication result is set to OK (S1250) and the determination result is returned to the CPU <NUM>.

As the result of the step S1220, if the start-up condition controller <NUM> determines that there is no match, the counter <NUM> adds <NUM> to the number of password mismatches <NUM> stored in the data storage area <NUM> of the storage <NUM> (S1230).

Next, the start-up condition controller <NUM> compares the number of password mismatches <NUM> with a second threshold value <NUM> stored in a parameter storage area of the storage <NUM> (S1240). If the start-up condition controller <NUM> determines that the number of password mismatches <NUM> exceeds the second threshold value <NUM>, the password authentication result is set to NG (S1260) and the determination result is returned to the CPU <NUM>.

When the start-up condition controller <NUM> compares the number of password mismatches <NUM> with the second threshold value <NUM> stored in the parameter storage area of the storage <NUM> (S1240), if the start-up condition controller <NUM> determines that the number of password mismatches <NUM> is equal to the second threshold value <NUM> or is smaller than the second threshold value <NUM>, the password authentication result is set to retry (S1270) and the determination result is returned to the CPU <NUM>.

The CPU <NUM> determines the password authentication result from the start-up condition controller <NUM>, and if the password authentication result is OK, the CPU continues the start-up of the main controller.

When the CPU <NUM> determines the password authentication result from the start-up condition controller <NUM>, and if the password authentication result is NG, the CPU instructs the display <NUM> to display a message that the start-up is not possible, and then performs the operation stop of the main controller <NUM> shown in <FIG>.

The CPU <NUM> determines the password authentication result from the start-up condition controller <NUM>, and if the password authentication result is retry, the CPU instructs the input part <NUM> to input the password and the display <NUM> to display the password again, and repeats the password confirmation step (S120).

Next, an operation stop information updating step when the operation stop of the main controller <NUM> is performed will be described. In the operation stop information updating step, when the CPU <NUM> detects the operation stop of the main controller <NUM>, the CPU <NUM> notifies the start-up condition controller <NUM> of the operation stop, and the start-up condition controller <NUM> performs the operation shown in <FIG>.

For example, the start-up condition controller <NUM> performs determination of an operation stop state (S1300) to determine whether the operation stop state is a normal state or an abnormal state. Here, the normal state is, for example, a case where the operation stop of the main controller <NUM> is performed according to a regular procedure, and the abnormal state is, for example, a sudden power failure, a forced power off, or a forced termination due to a failure in the start-up condition execution.

The start-up condition controller <NUM> does nothing and notifies the CPU <NUM> of continuing the operation stop of the main controller <NUM> if the operation stop state (S1300) determination is an abnormal state.

If it is determined that the operation stop state (S1300) is normal, the start-up condition controller <NUM> acquires operation stop date and time information of the main controller <NUM> by the clock function of the main controller <NUM> and stores it in the operation stop information <NUM> of the storage <NUM>.

Next, the start-up condition controller <NUM> acquires the start-up condition execution status information <NUM> stored in the storage <NUM> and checks whether the start-up condition execution status information <NUM> is valid or invalid. If it is valid, the start-up condition controller <NUM> does nothing and notifies the CPU <NUM> of continuing the operation of the main controller.

When the start-up condition execution status information <NUM> is invalid, the counter <NUM> adds <NUM> to the operation stop count <NUM> indicating the number of times of operation stop of the storage <NUM> and notifies the CPU <NUM> of continuing the operation stop of the main controller.

<FIG> shows the setting operation of the start-up condition execution status information <NUM> for performing authentication determination when the main controller <NUM> is started. The setting operation includes, for example, a start-up condition execution status information confirmation step (S200) of determining whether or not the setting of the start-up condition execution status information <NUM> is required, an operation stop count confirmation step (S210) of performing the setting determination of the start-up condition execution status information <NUM> from the operation stop count <NUM> stored in the storage <NUM>, and a management information connection confirmation step (S220) of performing the setting determination of the start-up condition execution status information <NUM> from the management device connection state <NUM> stored in the storage.

Next, the start-up condition execution status information confirmation step S200 will be described. In the start-up condition execution status information confirmation step S200, according to an instruction from the CPU <NUM>, the start-up condition controller <NUM> acquires the setting state of the start-up condition execution status information <NUM> stored in the storage <NUM> and confirms the acquired start-up condition execution status information <NUM>. If the start-up condition execution status information <NUM> is set to valid, the start-up condition controller <NUM> does nothing and returns a response to the CPU <NUM>. When the start-up condition execution status information <NUM> is set to invalid, the start-up condition controller <NUM> performs the operation stop count confirmation step (S210).

Next, the operation stop count confirmation step S210 will be described. In the operation stop count confirmation step S210, the operation stop confirmation operation shown in <FIG> is performed. The operation stop count <NUM> stored in the storage <NUM> is acquired (S2000), the third threshold information <NUM> stored in the parameter storage <NUM> of the storage <NUM> is acquired, and the operation stop count <NUM> is compared with the third threshold information <NUM> (<NUM>).

If the operation stop count <NUM> is equal to or less than the third threshold information <NUM>, nothing is done and the operation stop confirmation operation ends.

If the operation stop count <NUM> exceeds the third threshold information <NUM>, the setting state of the start-up condition execution status information <NUM> is set to valid (S2020) and is stored in the storage <NUM>, and the process exits.

Next, the management device connection confirmation step S220 will be described. This step is performed when the start-up condition execution status information <NUM> is not set to valid in the operation stop count confirmation step S210. In the management device connection confirmation step S220, the management device connection confirmation operation shown in <FIG> is performed. The management device connection state <NUM> stored in the storage <NUM> is acquired (S2100), and the connection state of the management device <NUM> is confirmed (S2110).

If the management device <NUM> is in an unconnected state, the management device connection confirmation step S220 is terminated without doing anything. If the management device <NUM> is in a connected state, the setting state of the start-up condition execution status information <NUM> is set to valid (S2130) and is stored in the storage <NUM>, and the process exits.

In the present embodiment, by setting the start-up condition execution status information <NUM>, for example, since unnecessary password authentication is not performed at the time of setup before a new device is connected to the management device <NUM>, it is possible to prevent a decrease in work efficiency related to a setup step.

Furthermore, in the present embodiment, by setting the start-up condition execution status information <NUM>, it is possible to prevent work loss in the setup step due to an erroneous operation by an unfamiliar worker and thus prevent a decrease in work efficiency related to the setup step.

Although the first embodiment and the second embodiment of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments, and can be modified in various forms without departing from the gist thereof.

In the above-described embodiments, an example of forming a film using a batch-type substrate processing apparatus <NUM> that processes a plurality of substrates at once has been described. The present disclosure is not limited to the above-described embodiments, and can also be suitably applied, for example, to a case of forming a film using a single-wafer type substrate processing apparatus that processes one or several substrates at a time. Even when the single-wafer type substrate processing apparatus is used, it is possible to restrict start-up of an apparatus controller by password authentication at the time of start-up and thus prevent the start-up in a state in which the apparatus setup is incomplete. Further, in the above-described embodiments, an example of forming a film using a substrate processing apparatus having a hot-wall type process furnace has been described. The present disclosure is not limited to the above-described embodiments, and can also be suitably applied to a case of forming a film using a substrate processing apparatus having a cold-wall type process furnace.

According to the present disclosure in some embodiments, it is possible to perform efficient setup by preventing an erroneous operation during setup of a substrate processing apparatus.

Claim 1:
A substrate processing apparatus (<NUM>) comprising:
a process chamber (<NUM>) configured to be capable of processing a substrate (<NUM>);
a main controller (<NUM>) configured to be capable of controlling the processing of the substrate (<NUM>);
a storage (<NUM>) configured to be capable of storing start-up condition execution status information (<NUM>) used to determine whether or not a start-up condition is executed when the main controller (<NUM>) is started, start-up condition management information (<NUM>) for managing the start-up condition, and a state of the start-up condition management information (<NUM>); and
a start-up condition controller (<NUM>) configured to be capable of validating the start-up condition execution status information (<NUM>) when the start-up condition management information (<NUM>) satisfies a predetermined condition.