global test operations demand transparency and automation ... · • hybrid it infrastructure...
TRANSCRIPT
Global Test Operations Demand Transparency and Automation for Rapid
Leveraging of Data and Enhanced Competitiveness
Debbora AhlgrenVP Sales & Marketing
OptimalTest
Tutorial Outline
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• Trends/Pitfalls/Challenges
• Improved Business Model
• Define Control/Monitor For Test Operations
• Focus on Early Detection/Warning Process
• ‐Why/What/How/ROI
• Global Test Operations
• ‐ IDM, Fabless, Foundry, OSAT
• IT Configuration Options
• Benefits/Risk Mitigation for Early Detection
• Low Risk/High Return Solution
• ‐ Yield, Cost, Operational Efficiency, TTM
• Summary
• Migration to Fabless Model with Multiple Foundries & OSATs
• Geographically Dispersed Integrated Enterprises
• Rising Complexity of Deep Sub Micron Devices
‐ Data Explosion: Device Size and Difficulty In
Isolating Systematic Faults
• Increasing Consumer Driven Marketplace
Industry Trends
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• Hybrid IT Infrastructure – Networks, Databases &
Software Tools
• Home Brewed Software Fills The Gaps
• Data Integrity Always An Issue
• Sub‐optimized Supplier Approach VS End‐to‐End
Optimization
• Lack of Trust/Transparency Among Partners
Challenges With Today’s Model
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• Overall Operational Efficiency Suffers
• Lost/Incomplete Data/Data Not Used
• Delay In Reacting To Issues/Changes
• Problem Ownership/Resolution Not Crisp
• Impacts Yield, TT, TTM, Re‐test, Quality, etc.
Shortcomings With Current Model
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• Requires Software Based Solution To Turn Data Into Actionable Information On Demand
• Vision Must Be Shared Across Supply Chain Allowing Adequate Transparency
• Today’s IT Networks, Database Management, Software Analysis Tools Provide Mature Enablement
• Optimizes Entire Supply Chain Benefiting All Partners
Holistic Solution For Supply Chain
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• Real Time Control – Station Controller on Test Cell for Real Time TTR, Yield Reclamation, Efficiency, Outlier Detection
• Real Time Monitoring – Control Room View of Fleet of Testers in Real Time for Yield Degradation Prevention, Efficiency, Immediate Quality Attention
• Near Time Early Detection – Early Detection Engine, Notification Application & Dashboard for Product & Testing Issues: Yield, Degradation Prevention & Reclamation, Efficiency and Quality
• Off‐line Analysis & Simulation – All Test Results, All Products, All Testers, Processes. Simulation Analysis & Reporting Tool Applications for TTR, Yield, Efficiency, Outlier Detection, Quality
Levels of Control/Monitoring for Test Ops
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• Real Time Detection Is Great, But‐ Requires Station Controller‐ Lacks “Horizontal” Fleet Control
• Most Issues Detected Based On MANY Lots & Testers‐ 60% Found With Near Time Early Detection
• Implementation Less Intrusive Than Real Time• Provides Baseline of Fleet, Product & Process• Re‐evaluation of Test Results Across Other Devices and Testers
Focus On Early Detection Solution
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• Early Detection/Warning Process Leverages Actionable Data In Near Real Time
• Identifies Emerging Issues Prior To Significant Impact
• Early Detection Engine Automatically Scans Data To Identify Issues
• Automated Near Real Time Monitoring and Reporting
• Includes Next Step Recommendations
Transparency Across The Supply Chain
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• Re‐evaluation of All Test Results – Control, Quality & Health Check. Detects Issues & Inefficiencies for: Yield, TT, Productivity, Quality & Data Integrity
• Detects Outlier Equipment – Finds Trending & Marginal Equipment Before Becoming Significant
• Monitor Product Indicators – Test Program Instabilities & Marginalities, Bin Switching, Yields, etc
• Detects Operational Issues – Pauses, Set‐ups, Re‐test
• Verifies Correct Product Flow & Disposition
What Early Detection Solution Does
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• Data Logs Captured From Any Origin & Any Format Immediately After Each Run/Pass/Execution‐ Data Sources: Station Controller, Software Proxy On Tester Or Data Stream Such As STDF
• Data Scanned Using Automated Rule Engines‐ Product Level Rules After Each New Data Log‐ Cross Entity Rules After Each Shift or Per Day
• Automated Action Taken Once Issue Is Detected‐ Email or Alert Including Possible Corrective Action
How Early Detection Solution Works
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Architecture of Early detection solution
Data Scan Engines
Common DB
Rule FeedbackScheduled Analysis and
Reports
Any Other Testers
Email Notification
Product Rule Engine
(End of Wafer or Lot)
Cross Entity
Rule Engine(End of
Shift or Day)
DispositionAutomatic Disposition(e.g. hold/release lot)
Eng. Defines Rules
Station Controller
With attached report
ProxyDashboard
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• Issue Within Test Cell‐ Data Log Completed At End of Wafer‐ Next Wafer Starts Test While Early Detection Engine Scans Data‐ If Issue Found on 1st Wafer, Warning Issued, Action Taken
• Issue With Fleet Comparison‐ Data Logs Are Captured From All Testers‐ At End of Shift or Daily, Early Detection Engine Looks For Outliers VSBaseline (i.e. Test Time Always Lower Than Rest of Fleet)‐ If Outlier Found, Warning Issued, Action Taken
• Possible Warning Methods‐ Email or Dashboard Alert‐ Connection To Work Flow System Issues a Hold‐ Proxy On Tester Can Stop Tester If Required
Early Detection Examples
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• Significantly Improves Data Integrity
• Provides Higher Overall Quality
• Fewer Test Escapes Without Alarming Customer
• Superior Operational Efficiency
• Tighter Control On Test Times, Test Program Releases
Early Detection Leverages Actionable Data
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• Prevents Yield Degradation
• Enables Yield Reclamation
• Significantly Lowers Retest
• Accelerates Yield Learning
• Reduces Capital Expenditures
Additional Early Detection Benefits
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• Previously Showed Early Detection/Warning Process For One Set of Products & One Test Floor Fleet
• Applies To Testing Sites Of IDMS, Fabless, Foundries & OSATs
• Value In Implementing Across Multiple Sites
• Provides Near‐time Capability Worldwide For Supply Chain Management
• Additional Off‐line Capability For Corporate Level To Monitor Business Units/Divisions Worldwide
Early Detection Across Global Operations
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IDM Europe• Near-Time• Off-Line
• Full Remote capabilities
Taiwan Operations•Real-Time•Near-Time
•Off-line
Singapore Operations•Real-Time•Near-Time
•Off-line
Korea Operations•Near-Time
•Off-line
China Operations•Near-Time
•Off-line
Early Detection across the IDMSite or supply chain
•Station Controller •Real-Time –Proxy
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Fabless US• Near-Time• Off-Line
Taiwan Operations•Near-Time
Foundries• Real-Time
OSATs• Real-Time
Singapore Operations•Near-Time
Foundries• Real-Time
OSATs• Real-Time
Korea Operations•Near-Time
Foundries• Real-Time
OSATs• Real-Time
China Operations•Near-Time
OSATs• Real-Time
US Operations•Near-Time
Foundries• Real-Time
Early Detection across the Fabless supply chain
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Foundry Taiwan• Near-Time• Off-Line
Taiwan OSAT-1 Singapore OSAT Korea OSAT
Taiwan OSAT-2
Early Detection across the Foundry:It’s Site or Supply chain - (Testing network)
Station Controller
China OSAT
Taiwan OSAT-3
STDFProxy
STDF
STDF
STDF
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OSAT Taiwan• Near-Time• Off-Line
Taiwan OSAT-1 Singapore OSAT Korea OSAT
Early Detection across the OSAT:It’s Site or Supply chain
Station Controller
China OSAT
STDFProxy
STDF
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Operationally – how does it work?Global Test Operations solution
• Headquarters • Servers, DB & Applications (Scan Engines, Reports or Dashboard)
• Clients to the Testing team & Operations team
• Regional operations–2 mode of communications:
• Terminal server via headquarters with remote access, OR
• Local regional installation - Servers, DB & Applications (Scan Engines, Reports, Dashboard) with Clients
• Data*: From Subcons/operations Headquarter : 3 options that can work all together• Station Controller (Meaning Subcon has Station Controllers installed on some of their testers at their site)
• Proxy originator (Meaning Subcon has Proxy installed on some/all of their testers at their site)
• Any Data-log from a Data Stream (STDF) (Meaning Subcon/Operations have some testers that don’t have controllers or a proxy)
• Turning the data into Actionable data • Once the data is in the Headquarters data-bases it is being processed and serves 2 purposes:
• Early detection solution : E-Mails ,Reports, Dashboard,
• Analysis & simulation: (i.e Adaptive TTR, Bin switching etc)
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Global Operations ‐IT Configurations options :
Headquarters
Configuration 3Foundry/OSAT
Configuration 2Foundry/OSAT
Configuration 1Foundry/OSAT
TW, Kr, Ch, Sing Etc
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• Time to Actionable Data Reduced From Hours or Days To Minutes
• Data Integrity Clarifies Cost Issues Within Supply Chain
• Early Detection Solution Scalable
‐ Real Time Advanced Adaptive Testing
‐ Aggressive Test Time Reduction
‐ Comprehensive Outlier Detection Solutions
Additional Supply Chain Optimization
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• Non‐Intrusive
• Easily To Implement With Legacy Systems
• Non Mission Critical
• Low Cost Support
• Immediate Benefits with Quick ROI
Risk Mitigation
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• Actionable Data Drives The Results
• Strategic Solution Scales With Business Model, Geography & Technical Requirements
• Benefits All Supply Chain Partners
• Significant Improvements To Key Metrics‐ Yield, Cost, Operational Efficiency, Time To Market
Low Risk/High Return Solution
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• Near Time Early Detection Solution Optimizes Entire Supply Chain With Adaptive Learning
• Accurate, Effective, Timely
• Data‐‐‐ Information‐‐‐ Knowledge‐‐‐ Action
• How Does Your Supply Chain Measure Up?
Summary
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