our people are our future - nmi€¦ · john guerin mtm teresa counihan mtm . safety focus group...
TRANSCRIPT
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MAIREAD SHINNORS
ANALOG DEVICES INTERNATIONAL
LIMERICK
IRELAND
Our People are our
Future
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ADI celebrates 50 years in Business
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Communications
Industrial
Instrumentation
Portable Media Audio/Video
Medical Imaging
Industrial Instrumentation
Communications
Computer Portable Media
Medical Imaging
Audio/Video
Analog Devices Inc. What do we do ?
A global leader in high-performance semiconductors for signal processing applications Covert Real world Signals to Digital
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Where do you find our products?
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Multi media Medical Imaging
Car’s Industrial Robots
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Analog Limerick Campus 40 Yrs. old next Year
Established in 1976 as ADI’s CMOS Facility.
Approximately 1100 employees.
State-of-the-art Mixed Signal Wafer Fabrication
ADI’s European Research and Development Centre is based in
Limerick, New building opened in 2015 which won the first LEED
Platinum award in Ireland.
Leadership in Energy & Environment Design
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OPEX Programs supports
ADI’s Operational Principals + Process Control Pyramid
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Safety
Safety Focus Group
Environment
6S Sustain
Materials
Back To Basics
Operations New Product
New Equipment
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ADI Limerick – Process Control & Continuous Improvement – 2014 /
2015
2014 / 2015 Operational Excellence Program Objectives:
SAFETY – Promote compliance to all SAFETY protocols on Site,
encouraging open discussion on improving systems and
communications through engagement.
The removal of obstacles to FLOW, through the application of Lean
Tools and systems.
The elimination of WASTE through the promotion of Cross functional
Collaboration, with the primary focus being at the tool level.
Utilise and engage the Talents of ALL EMPLOYEES to take
responsibility for identifying waste and obstacles to the delivery of
ADI’s Operating principles of Safety , Quality , Output and Value 4
Money -
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Your People are your Greatest Asset
How do you create an environment where people feel they are valued in the organisation ?
Encourage engagement by giving more tool ownership
Provide opportunities outside of their Primary Roles where they can develop Skills which will
enhance their career opportunities
Value your employee as well as the customers
Focus on development of Skills at the tool user level.
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Procedure Spec Updates
Historically all procedures were written by the Eng group .
Over the last 12 months all our production spec’s have been
rewritten my the MTM group in collaboration with the Eng group.
Different shifts took ownership for different WorkCentre's and these
Spec rewrites were project based.
► Less text More picture ‘ a picture is worth a thousand words ‘
► This reduced Spec size by 75% in some cases
► Precise and easy to use for training
► Plan is to insert Video’s into the specs to be used as training
aids.
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Back 2 Basics Program 2015 S
afe
ty
• Define Assessment – IPAD Model
• Fix / Task discrepancies
• Report Metric & Actions – Monthly EHS Rep meeting
• Support Safety Project Group >3mths.
En
viro
nm
en
t
• Cleanroom Conformance
• 6S Sustain Audit Program
• 2016 Airlock – Install Xmas
• Inkless Fab – Goal Jan 16
• Equipment Service & Support - Spares
Ma
teria
ls
• Silicon Storage – Boxes , Cassettes , Racks , Stockers, Internal Cleaning
• Silicon Handling – Transfer Tools , Notch Align, Compliance, Training and Awareness
• Silicon Management – Use / Reuse
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Keith Higgins
Manu Supervisor
John Guerin
MTM
Teresa Counihan
MTM
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Safety Focus Group
KEITH HIGGINS
MANUFACTURING SUPERVISOR
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Standard Safety in the workplace
► We are all responsible for our own safety and the safety of others in the workplace by adhering to
all safety procedures set in place. Good Practise and Good Standards.
► The EHS department is responsible for the overall safety of the Plant and the people who work
there.
Safety Statement
Monthly EHS Safety meetings
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Problems we wanted to Address
► Site Safety Spec LK00606
Written by the EHS Department for EHS ,
No interaction with the MTM’s post initial induction training on LK00606
► Lack of Engagement by the MTM’s in relation to ownership for safety issues on Shift.
► EHS monthly meeting
No time allocated for Reps to discuss issues/Concerns highlighted from their Shifts
Very little Personal Development training provided for MTM’s in relation to Safety
► 8 Point Safety handover
Paper based logbook
Not always completed
Book goes missing
Need and IT solution to replace logbook
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Safety - Safety Focus Group
► SAFETY – Promote compliance to all Safety protocols on Site, encouraging open discussion on
improving systems and communications through engagement on Shift.
► Members
Keith Higgins ( Fab ) , Claire Frawley ( Probe )
EHS Reps / MTM’s
EHS – Elaine Egan / Anne Marie O Dwyer / Tara
► 14 members not including the EHS Department
All 14 have 3rd level Education in H+S
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Safety Focus GROUP
MTM’S
Technicians
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MTM EHS REP’S FETAC Trained
► Each shift has a EHS Reps , The safety reps receive an Initial 3 day course and then a refresher course every 3 years.
The course covers at a top level:
Health & Safety Legislation
Role and Function of the Safety Representative and Safety Consultation.
Hazard risk assessments
Accident investigation and reporting
Active and reactive monitoring
Effective communication skills
The EHS Rep attends the Monthly EHS meeting and raises any issues or concerns they have on behalf of
their shift.
The EHS Reps are members of the Safety Focus Group
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► 8 point Safety handover
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Safety Focus Group
► Site Safety Spec LK00606
Focus on improving MTM Awareness &Interaction with the Site Safety Spec
MTM’S to rewrite the Spec in the same format as the Operation Spec’s
Recertification being reviewed annually.
► EHS monthly meetings
EHS MTM REP’s now have a 15 minute slot at the monthly meeting where they report on Audit discrepancy’s and present Shift safety concerns and solutions.
An IPad App was sourced to replace the logbook
EHS Reps completed the audit daily.
Questions are scoring and weighted.
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► VDA6 Audit Manager – IPAD APP
► Corrective Actions within Manufacturing control
► Metric Based scoring App
► Fix it , Tasks or Project’s Projects owned by the EHS Department
► Capture Idea’s and Suggestions to Improve
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Audit Discrepancies
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Audit Examples
► IPad APP
Data Base for collecting Discrepancies i.e. Photo’s
► Metric Based, scored accordance to adherence
► Some other examples of on shift discrepancies
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Conclusion
► Safety Focus Group has given the MTM’s, Tec’s and Supervisors on shift a vehicle to
Audit , Assess and Fix on shift Safety discrepancy Task's .
► By providing Training for the EHS Reps they are now confident with their skill and knowledge to
participate on projects with the EHS group.
► By Investing in your people you are investing in your future.
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Inkless /Paperless Fab Project
JOHN GUERIN
8’ WAFER FAB MTM
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Inkless Fab
► The issue of Graffiti /Biro marks were highlighted through our 6S Audits.
► History of Ink damage in the Fab
Both Legacy and recent – Accidental & Deliberate – Hard to remove
Suits being dumped as unable to remove Ink in Cleanroom Wash cycle
► Our solution was to go inkless in FAB
Ink is a metallic contaminate,
6S Shine golden tool required us to remove all biro marks from equipment .
Ink damage does not look good when showing Customers around .
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Alternatives to the notebook and Pen
► All requirements were identified across all functional groups in relation to data and information
storage , Biro’s , note books , logbooks ,manuals and spreadsheets etc.
► A replacement for these was sourced to be used in a trial.
► MTM’S recommended Boogie boards to replace their notebooks and designed a way to attach a
boogie board to the production Trolleys.
► Supervisors used a boogie board that can store data if required
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Information Management –
Equipment and Engineering ,
• Books are Stored @ Desks – Brought in / out
of Fab – Poor Housekeeping
• Not shared with other members of the Team
• No standard method for record keeping
• Not Searchable – Hard to find specific notes,
results and experiments
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► 27 Notebooks@$13
► $350
► 1 tablet 400e
Versus
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Hardware Trialled
• Several devices were trialled.
• Hardware of choice was the Dell 10” Tablet.
• Windows based software.
• OneNote used as primary software tool.
• This started out as an inkless fab project but has turned out to be far more successful and have now become more of an information management project. The benefits are endless.
• All groups very impressed and very eager to get involved, the general consensus of the guys participating in the trail is that they will never go back to a notebook again.
• Full Trial approved for the IPD area . WIFI connected and Tablets in place .
• Rollout to other area’s expected early next year, Boogie boards already in place in all areas.
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Wafer Handling Improvement Team
TERESA COUNIHAN
MANUFACTURING MTM
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The Problem
► Defects and scrap due to mishandling of wafers by individuals and tools
► A Cross Functional Team of Eng’s ,Equip Tec’s and MTM’s was put in place to look at all aspects of
Wafer Mishandling .
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Materials & Handling Transfer Tool Team
►Goals
►Transfer Tools - Teresa Counihan MTM – Reduce occurrence of handling & near-miss scrap incidences
– Improve performance & uptime of transfer tools
► Manual Handling , Notch Aligners - Shane McLaughlin MTM
– Identify areas & implement solutions to reduce handling (Notch aligners)
►Training & Awareness - Mairead O Connor MTM – Back to Basics
– Set standards and roll-out training to all groups
– Induction training and create training material
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Transfer tools
RAPIDRANS Vertical Transfer
FSI, EPI, WB4/WB6
IDLWs Vertical Transfer
WB5, 65FSI splitting
AWTs Automatic
Horizontal Slide Transfer
FSIs
GATs Manual
Horizontal Slide Transfer
Varians, Transfer room
BPP8s Horizontal
Batch Pick and Place
Semitools
SPP8s Horizontal
Single Pick and Place
Diff, Litho isles, CMP tool, IPD
UV cures
27 tools in total across all tool types
Type Description Tools serviced
Transfer tools Transfes Transfer Tools
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Issue 1: Undetected FSI Cassettes (A192-81MJ-26)
New type Carrier switches do not have enough travel tolerance to detect the presence of White FSI Cassettes.
• Traditionally, the older type Carrier switches could be wound up or down.
• This is not best practice.
• Carrier switches should not need to be adjusted.
• Switch tolerances should be wider to accommodate various FSI cassette profiles.
A192-81MJ-
26 FSI
Cassette
Carrier
Switch
AWT Historical issue
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Issue 2 : Wafer Bumping during Transfer
This problem occurs when the pusher arm fails to transfer wafers from one cassette type to another.
• Usually more frequent when transferring the maximum load of 25 wafers.
• Occurs on all AWT tools.
• To recover from this error, the operator needs to reset the tool and repeat the transfer step.
Vendor Solution: A new modified mother board (Rev C) is available and is installed in 62AWT. However, as this tool failed to run since its refurbishment, this mother board has not yet been qualified.
Pusher
Arm
AWT Historical Issues: AWT historical issues
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AWT Historical Issues: Issue 3: Slipping Motor Gear Head
This issue causes the belt to intermittently slip and not operate the pusher arm.
The Gear head is attached to the Motor shaft using a ‘Nyloc’ nut which if removed frequently loses its tightening effect.
Analog Solution: A single grub screw drilled through the gear head and through the motor shaft. The drill hole on the gear head is counter sunk to prevent damage to the belt.
Nyloc
Nut
Grub
Screw
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Vendor Site Visit
► When the issues were highlighted to the Vendor they were insistent that all these errors had been
tested for during the manufacturing process and no issues arose.
► It was decided that a site visit to the vendor was appropriate to help identify the cause of the
problems.
We brought an example of the Teflon boats which we use as most of our problems occurred when
transferring wafers to and from these boats.
► We wanted to address the 3 main problems that I previously highlighted .
Bumping
Arm failing to retract due to a slipping Motor Gear Head
Undetected FSI Cassettes
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On Site Test Evaluation:
1. Failure to Detect FSI Cassettes:
► Provided an existing FSI cassette which had been recently used in 62FSI.
► Reproduced error on 62AWT in the presence of the Vendor engineers.
► Established that the cassette used by the vendor was a virgin cassette and never used in the FSI process.
► Identified fundamental difference between both cassette profiles.
► The problem identified was that the cassette profile is effected over time due to the FSI process.
► Requested that the type of Carrier switch be changed to accommodate varying profiles.
► The Vendor insisted on maintaining current switches as they use a Micro-switch activator instead of spring
loaded sensor which they believe is more accurate and prevents carrier misplacement problems.
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On Site Test Evaluation:
2. Slipping Motor Gear Head:
► Vendor acknowledged that this was not a good design.
► Vendor to discuss internally the possibility of implementing a design change.
► Note: For 62AWT, EMU have replaced the ‘Nyloc’ nut with a conventional nut instead.
3. Wafer Bumping During Transfer:
► Frequency of this error presented to the Vendor as a snap shot from a typical 12 hour shift.
► This problem has yet to be qualified with Rev. C mother board.
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Closing Actions:
► To follow up with Vendor and ensure hardware changes are implemented to the Motor gear head for
all AWT tools.
► To ensure that vibration testing is also included as part of AWT final test sequence.
► To ensure AWT tool recognises the warped profile of the FSI Cassette.
► Analog training spec’ to be updated to include revised safety operation of AWT i.e. pusher arm will no
longer retract when the front Cassette is lifted. A consequence of the new Rev C. mother board.
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Teresa – My Journey in Analog
► I am with the company 18 Years , I am an MTM in the Diffusion and Imp area of Fab .
► Outside my core role I have had the opportunity to develop in the following areas.
Redesigned and created new spec’s in my area. I am currently working on inserting Video as a training aid
within the spec’s.
Knowledge Assessments, I worked with an Engineering to create a Knowledge Assessment process in Diff.
Knowledge Assessor, I trained as an assessor and now I assess in the Diff area .
Previous to this MTM’S could only be assessed by an Eng or Supervisor.
I participate in Improvement projects, Site visits and interact with tool suppliers to better improve my work
area.
I have been trained as an ERT (Emergency Response Team Member).
As you can see here
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Conclusion
► Any Question ?
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