nvq level 2 business improvement - nmi...equipment engineer communicated that each individual nxe...
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Seagate Confidential
Name: Richard Kernaghan Date : Sep 2016
NVQ Level 2 Business Improvement
Seagate Confidential
Project title: Optimize NXE run start procedure
Project Team : Richard Kernaghan (BIT operator)
Paschal McKenna (Trainer)
Kevin Crumley (Area UM)
Alister Gourley (Lead operator)
Cain Nash (Process Engineer)
Paddy Kealy (Process Engineer)
Stephen McElhinney (Eqp Engineer)
Andrew Gillespie (IE)
NVQ Level 2 Business Improvement Techniques
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Project Lead Team Members
Problem Statement:
NVQ Business Improvement Techniques - Level 2
Project Title
Optimize NXE run start procedure
Richard Kernaghan (BIT operator)
Paschal McKenna (Trainer)
Alister Gourley (Lead operator)
Kevin Crumley (Area UM)
Cain Nash (Process Engineer)
Paddy Kealy (Process Engineer)
Stephen McElhinney (Equipment Engineer)
Andrew Gillespie (IE)
Project Co-ordinator
Level 3
Richard Kernaghan
Tool start process requires operator interaction to initiate cassette
mapping. The time lost is not visible on tool view.
Paschal McKenna
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Project Title: Optimize NXE run start procedure
8D Action Status
D1 Define the Team Complete
D2 Describe Problem Complete
D3 Containment Plan Complete
D4 Describe the Cause Complete
D5 Choose/ Verify Corrective Actions & Solutions Complete
D6 Implement / Validate Permanent corrective Actions Complete
D7 Preventative Action Plan Complete
D8 Congratulate the Team Complete
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D1 Define the Team D1 Complete 02/09/2016
Team Members:
Richard Kernaghan (BIT Operator)
Paschal McKenna (Trainer)
Alister Gourley (Lead Operator)
Kevin Crumley (Area UM)
Patrick Kealy (Process Engineer)
Cian Nash (Process Engineer)
Stephen McElhinney (Equipment Engineer)
Andrew Gillespie (Industrial Engineer)
Project Title: Optimize NXE run start procedure
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Project Title: Optimize NXE run start procedure
D2 Describe Problem D2 Complete 10/09/2016
Current procedure requires the operator to
press Load on the SOC and then wait a
period of time for Map Cassette to become
active on the Toolset. This needs to be
clicked on before the run will commence
and currently Toolview accepts SOC as
the trigger that the tool has started and
has no visibility if this is not the case.
Toolview shows NXE_52, the run is still in
process 11 minutes after it was due to
complete. It is suspected there was a
delay in the cassette been mapped.
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Project Title: Optimize NXE run start procedure
D2 Describe Problem D2 Complete 08/09/2016
30 Days data showing the time from Load being pressed
until tool mapping is started @ STST & NRM
Here in STST we lose out on 3 mins/run with 14000 runs
being processed during this period!!!
NRM have auto mapping already in place
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Impact/ Risk Assessment
Containment Actions
Project Title: Optimize NXE run start procedure
D3 Containment Plan D3 Complete 30/09/2016
Velocity suffering due to Production time being lost
Trust the operators to map the cassette quickly
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Project Title: Optimize NXE run start procedure
D4 Describe the Cause D4 Complete 06/10/2016
4 Why’s
Time lost mostly every run
Tool requires operator interaction
Delphi logbooks unable to auto start mapping
Historical Safety feature in place
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Project Title: Optimize NXE run start procedure
D5 Choose/ Verify Corrective Actions Solutions D5 Complete 13/10/2016
SOC now has the capability to initiate auto mapping Get agreement from all parties to turn function on
Before any changes can be made the Process Engineer needs the
current MP to be re-evaluated to reflect current best practice Complete and agreed with Process Owner
Equipment Engineer communicated that each individual NXE needs this
functionality to be turned on while idle and needs monitored closely
initially Equipment group had/have a fear that this could increase the possibility of a
scrap event due to double etch. This is/was the biggest obstacle to
implementation.
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Project Title: Optimize NXE run start procedure
D6 Implement/ Validate Permanent Corrective Actions D6 Complete 20/10/2016
• PCA has now been
distributed and has
received signoff
• This has allowed us to
start on a number of
toolsets in Fab1 ensuring
that everything is in place
before some of the more
critical operations in Fab2
are turned on
• We will revisit in 3 months
time to measure actual
improvement v theoretical.
Assuming we are able to match NRM figures
What we were able to process in 90 days we will now be able to
process in 86.3 days. An improvement of 4.2%
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Project Title: Optimize NXE run start procedure
D6 Implement/ Validate Permanent Corrective Actions D6 Complete 20/12/2016
Preliminary data is showing an improvement
Before:
6:30 mins
Now:
4.40 mins
This is over a period of 11111 runs and includes
the process of getting each individual NXE
upgraded.
We expect these figures to improve further as the
data will reflect all Tools having the upgrade.
1:50 min/run gained which can equal = 340 hours production
opportunity gained per month across the Toolset group
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Project Title: Optimize NXE run start procedure
D7 Preventative Action Plan D7 Complete
Ensure that this upgrade is not switched off or disabled for any
reason
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Project Title: Optimize NXE run start procedure
D8 Congratulate the Team D8 Complete 02/11/2016
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Appendices