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COPY EXACTLY!

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Goal: Explain the Copy Exactly! (CE!) methodology for Intel

suppliers to align themselves to support the goals and objectives associated with the Virtual Factory.

Objective:Define what is Copy Exactly! (CE!)Explain the scope of CE!Employ best known method’s (BKM’s) to get to CE!Explain and describe the impact of not copying exactly

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VF CE! CE! - Copy Exactly!

A process…not an end result…that facilitates quick deployment of product or system to completion.

A historical process driven by start-up TD-to-Fab experience.

A set of organizational tools proven to produce results.

An ongoing Management challenge.

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Hilosophy… Why CE! Identical inputs to identical equipment will produce identical results

Physics Works!

Non-identical input and equipment are unlikely to product identical results Even if we achieve matching on gross measurements.

Small differences can cause BIG problems later on.

We don’t know what we don’t know.

By copying inputs/equipment exactly from existing to new factories, we are guaranteed identical output.

We knowingly surrender upside (“innovation”) to avoid downside. History shows downside,not upside, results from deviation. We are not technically smart enough to make changes during transfer

without unplanned negative consequences.

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Copy Exactly! : History

History of four major (Fab) process transfers spanning over 10 years

shows that CE! works(and non-CE! doesn’t!)

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Learning From Past Process Ramps

The wrong “Engineering Judgment” when deviating from the development process during process transfer will collapse die yield and output and impact competitiveness.

Seemingly unimportant differences in equipment inputs can result in yield, reliability and/or performance differences.

Process technologies are so complex that traditional “Engineering Judgement” is not sufficient to prevent problems.

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The Copy Exactly! System Copy Exactly! Scope

Copy Exactly! includes everything… Facilities and Tool Install Equipment Process flow Metrology and Materials Automation

Except… Org/ops structure WSPW Office Layouts

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Matching at all levelsSame physical inputsStatistically matched

responses (outputs)

Keeping matchedCoordinated changesAuditsProcess control system Joint Fab mgmt

structure

The Copy Exactly! SystemCopy Exactly! Matching

Equipment/Process:-Etch/Dep Rates -Thicknesses-Particles -Film Comp

Physical Inputs:-Recipes -Chemicals -Clean room-Facilities -Gases -Equipment

Module:-CD’s -SEM-Visual -Electrical

Product: -Yield -Reliability

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Copy Exactly! ResultsDie Yield Comparison - With/Without

CE! 0 10 20 30 40 50 60

# of Months

Lo

g (

Die

Yie

ld)

With Copy Exactly!Intel 0.5m; P852

Without Copy Exactly!Intel 1m; P648

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Copy Exactly! -- An Ongoing Management Challenge

Innovation and Copy Exactly!

“Reasons we Can’t Do It”

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Management Challenge Reasons We Can’t CE!

Whenever CE! is tried with a new population, we hear: “We don’t need to copy this because we understand the impact of deviations.”

(or...”because this is obviously trivial.”) “We can’t copy this because it will require too much money/time/effort.” “We agreed to not copy this item by mutual agreement.” “We shouldn’t copy because it reduces innovation.” “We shouldn’t copy because we have a much better idea here.” “We are used to bringing our product up from scratch”

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Management Challenge - Reasons We Can’t CE!

Experience has shown that:These issues can all be overcome.We are not smart enough to pick and choose

what to copy without making mistakes.Constant Management vigilance is required to

overcome these objections and ensure CE!

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Copy Exactly! : Tools

As CE! evolved, we have developed a set of tools to drive the process

and ensure results.

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Innovation and Copy Exactly! Copy Exactly! is meant to control, not stifle, change. Copy Exactly! means change must happen for the process as a whole,

not the individual or group or system. A well-defined process exists for change:

Originator proposed change to working group. WG decides whether to proceed, based on VF or system

requirements. Originator prepares White Paper. White Paper is approved by XCCB system. Change is expected to happen in all plants and group

simultaneously.

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Innovation and Copy Exactly! -- Issues

The system has many steps and requires negotiation skills by the originator.

The system can seem overwhelming, discouraging innovation or encouraging undercover changes.

While issues directly impacting factory indicators get addressed quickly, other types of issues may be deprioritized.

Rapid yield improvement in CE! virtual factories proves the system can and does work, but it may need adjustment from time to time.

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SummaryCopy Exactly! :

Higher yields Product to market faster Larger profits for Intel Higher returns to shareholders!!!