Introduction to the MIG TDP template
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Transcript of Introduction to the MIG TDP template
COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff
The MEMS Industry Groups Technology Development Process Template (TDP)Improving multi-site, multi-disciplinary MEMS development collaboration
CONFIDENTIAL Process Relations GmbH
Slide 2
Negative Data
Comic by: Nik Papageorgiou http://upmic.wordpress.com/
CONFIDENTIAL Process Relations GmbH
Slide 3
Negative Data
Comic by: Nik Papageorgiou http://upmic.wordpress.com/
CONFIDENTIAL Process Relations GmbH
Slide 4
Negative Data
Comic by: Nik Papageorgiou http://upmic.wordpress.com/
CONFIDENTIAL Process Relations GmbH
Slide 5
Negative Data
Comic by: Nik Papageorgiou http://upmic.wordpress.com/
CONFIDENTIAL Process Relations GmbH
Slide 6
Why do I show this? – What are the challenges behind this?
Inappropiate data management in R&D
Inappropiate collaboration methodology
CONFIDENTIAL Process Relations GmbH
Slide 7
Agenda
Quick company introduction
The challenges in collaborative MEMS development
The methodological approach – MIG TDP Template
The next level – CORONA Methodology
Conclusions
COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff
About Process Relations GmbH
CONFIDENTIAL Process Relations GmbH
Slide 9
Process Relations’ Mission
…is to enable you to…
Expedite your R&D with improved Methodology and flexible Software solutions
Next generation recipe and DoE management Virtual manufacturing data management Automated data collection from various sources Experimental data management, analysis and extraction
We deliver the easy to use, unique, world class Process Development Execution System (PDES) and consulting services.
CONFIDENTIAL Process Relations GmbH
Slide 10
PDES Coverage of other Manufacturing Solutions
Business SystemsERP
Enterprise IT SW Infrastructure
CRMMDM
Inbound Supply Chain Systems
SCP
etc.
etc.
Operations Management
SystemePDES
MES
EMS LIMS
Operations IT SW Infrastructure
Design & Engineering Systems
Control and Automation Systems
RTD AmHS / MCS
SPC
APC
Manufacturing Tools
EI
RMS
QMS
Shipping Outbound Systems
TMS
etc.
SRM
Doc-Mgt
PLM
DwH
etc.
Doc-Mgt
COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff
The challenges in collaborative MEMS development
CONFIDENTIAL Process Relations GmbH
Slide 12
The challenges
25% development projects reach the market
of those 66% fail their original expectations
20% of projects take too long and miss their market window
35% of companies experience runaway projects
40% of R&D experiments are repeated
Source: IDC “Accelerating Science-Led Innovation for Competitive Advantage” Feb. 2012
CONFIDENTIAL Process Relations GmbH
Slide 13
Difficulties in collaborative MEMS development
Wealth of information / technologies / data / …
Diverse Variances, Options and Variability
Multi-disciplinary teams required
Collaboration along the value chain
CONFIDENTIAL Process Relations GmbH
Slide 14
Collaboration challenges
MEMS Development Phases must include Foundry at early stages with multi-disciplinary team
Design Review must be done for a transfer from R&D Lab to High Volume Manufacturing
…
14
Fabless Houses
Design HousesDesign Centres
MEMS ProcessDevelopment
Specialists
Assembly & Test Houses
(Wafer) Foundry Services, SemiconductorContract Munufacturer (SCM)
Integrated Semiconductor(Device Manufacturer (ISM/IDM)
Distributors, Fabless Houses,
Wholesalers, Trading
Companies
X-FabBusiness Model
CONFIDENTIAL Process Relations GmbH
Slide 15
Difficulties in collaborative MEMS development
Question: How to manage for fast time to market?
CONFIDENTIAL Process Relations GmbH
Slide 16
Historical Collaboration between Design and Process
Microlelectronics:Clear separation between manufacturing and application development
Micro Nano Technology: Fabrication effects influence all stages
Concept Behaviour FabricationStructure Geometry
De
sig
n R
ule
s
Concept Behaviour FabricationStructure Geometry ???
CONFIDENTIAL Process Relations GmbH
Slide 17
The Traditional Development Cycle for MEMS Device
IDEA
DEVICEDESIGN
EXPERIMENT
PROCESSDESIGN
COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff
The methodological approach – MIG TDP Template
CONFIDENTIAL Process Relations GmbH
Slide 19
The basis for the MIG Technology Development Process Template
CONFIDENTIAL Process Relations GmbH
Slide 20
Principle structure MIG TDP Template
CONFIDENTIAL Process Relations GmbH
Slide 21
MIG TDP Template -- Protocols / Roles & Responsibilities
Category Concept Feasibility Prototype Pilot Production
Maturity IdeaDesign Defined
Process EstablishedDesign and
Process QualifiedDesign Frozen
Process ValidatedDesign and
Process Frozen
Lead Engineer R&DR&D /
DevelopmentR&D /
DevelopmentDevelopment /Manufacturing
Manufacturing
Layout Design Team Design Team Design TeamProcess Mapping Process Team Process TeamProcess Development
Process Team Process Team Process Team
Process Improvement
Process Team Process Team
Processing Engineers EngineersEngineers / Operators
Operators Operators
Experimental Approach
ManufacturingPOC DOE
ManufacturingPOC DOE
Target specs and tolerances DOE
Process windowing DOE
Surface response DOE
Quality ProtocolsSafety and
EquipementSafety and
EquipementAdd Product
SubsetAdd Full Product Full
Process / Material /Equipment Changes
FrequentControlled Change
Qualification Required
Qualification Required
ChargeDevelopment
ProjectDevelopment
ProjectDevelopment
ProjectLot Charge
Yielded die / wafers
POC = Proof of Concept
Protocols / Roles and Responsibillities
CONFIDENTIAL Process Relations GmbH
Slide 22
MIG TDP Template -- Gating Requirement Examples
Category Concept Feasibility Prototype Pilot Production
Maturity IdeaDesign Defined
Process EstablishedDesign and
Process QualifiedDesign Frozen
Process ValidatedDesign and
Process Frozen
Lead Engineer R&DR&D /
DevelopmentR&D /
DevelopmentDevelopment /Manufacturing
Manufacturing
Layout Design Team Design Team Design TeamProcess Mapping Process Team Process TeamProcess Development
Process Team Process Team Process Team
Process Improvement
Process Team Process Team
Processing Engineers EngineersEngineers / Operators
Operators Operators
Experimental Approach
ManufacturingPOC DOE
ManufacturingPOC DOE
Target specs and tolerances DOE
Process windowing DOE
Surface response DOE
Quality ProtocolsSafety and
EquipementSafety and
EquipementAdd Product
SubsetAdd Full Product Full
Process / Material /Equipment Changes
FrequentControlled Change
Qualification Required
Qualification Required
ChargeDevelopment
ProjectDevelopment
ProjectDevelopment
ProjectLot Charge
Yielded die / wafers
POC = Proof of Concept
Protocols / Roles and Responsibillities
Category Concept Feasibility Prototype Pilot Production
Design Preliminary Test Freeze Optimize RevisionDesign Failure Mode and Effect Analysis
Preliminary FinalizeVerify
with Process
Process Failure Mode and Effect Analysis
Preliminary Finalized Adjust/ Revise
Process Flow Diagram Draft Preliminary Test Finalized FinalizedStatistical Processing Charts
DraftIdentify and
Establish ChartsPopulate/Setup
/ControlMonitor/OCAP
/AdjustEquipment Capability Study Test Identified Validated FinalizedProcess Capabilities for critical nodes
Study TestMeeting
physical specsCp > 1 Cp> 1.3
Yield Estimate Model InitialEstablish
baseline yieldsYield
improvement
Specifications DraftTarget
specificationsEstablish spec/
Acceptance criteriaSpecifications
in placeSpecifications
in placeBOM Draft Preliminary Finalize Frozen Frozen
Inventory Control StudyBuild demand
forecastInitial Plan In place
Adjust when required
Manufacturing Execution System
DraftBuild demand
forecastBuild models Models in place
Modify as necessary
Capacity/ Throughput
StudyBuild demand
forecastEstablish capacity/Identify constraints
Address constraints
Add capacity if required
Safety Study Identify Initiate Plan Rectify SustainShipping Protocols Schedule Identify Establish In place Frozen
Training Schedule Plan InitiateIssue
documentsRevised
documents
Pricing/Contract Development Development Development Manufacturing price in place
Adjust
External Vendors Establish Establish Qualify Qualified Qualified
BOM = Bill of Materials OCAP = Out of Control Action Plan
Gating Requirments
CONFIDENTIAL Process Relations GmbH
Slide 23
MIG TDP Template -- Expanded Design Requirements
Category Concept Feasibility Prototype Pilot Production
Maturity IdeaDesign Defined
Process EstablishedDesign and
Process QualifiedDesign Frozen
Process ValidatedDesign and
Process Frozen
Lead Engineer R&DR&D /
DevelopmentR&D /
DevelopmentDevelopment /Manufacturing
Manufacturing
Layout Design Team Design Team Design TeamProcess Mapping Process Team Process TeamProcess Development
Process Team Process Team Process Team
Process Improvement
Process Team Process Team
Processing Engineers EngineersEngineers / Operators
Operators Operators
Experimental Approach
ManufacturingPOC DOE
ManufacturingPOC DOE
Target specs and tolerances DOE
Process windowing DOE
Surface response DOE
Quality ProtocolsSafety and
EquipementSafety and
EquipementAdd Product
SubsetAdd Full Product Full
Process / Material /Equipment Changes
FrequentControlled Change
Qualification Required
Qualification Required
ChargeDevelopment
ProjectDevelopment
ProjectDevelopment
ProjectLot Charge
Yielded die / wafers
POC = Proof of Concept
Protocols / Roles and Responsibillities
Category Concept Feasibility Prototype Pilot Production
Design Preliminary Test Freeze Optimize RevisionDesign Failure Mode and Effect Analysis
Preliminary FinalizeVerify
with Process
Process Failure Mode and Effect Analysis
Preliminary Finalized Adjust/ Revise
Process Flow Diagram Draft Preliminary Test Finalized FinalizedStatistical Processing Charts
DraftIdentify and
Establish ChartsPopulate/Setup
/ControlMonitor/OCAP
/AdjustEquipment Capability Study Test Identified Validated FinalizedProcess Capabilities for critical nodes
Study TestMeeting
physical specsCp > 1 Cp> 1.3
Yield Estimate Model InitialEstablish
baseline yieldsYield
improvement
Specifications DraftTarget
specificationsEstablish spec/
Acceptance criteriaSpecifications
in placeSpecifications
in placeBOM Draft Preliminary Finalize Frozen Frozen
Inventory Control StudyBuild demand
forecastInitial Plan In place
Adjust when required
Manufacturing Execution System
DraftBuild demand
forecastBuild models Models in place
Modify as necessary
Capacity/ Throughput
StudyBuild demand
forecastEstablish capacity/Identify constraints
Address constraints
Add capacity if required
Safety Study Identify Initiate Plan Rectify SustainShipping Protocols Schedule Identify Establish In place Frozen
Training Schedule Plan InitiateIssue
documentsRevised
documents
Pricing/Contract Development Development Development Manufacturing price in place
Adjust
External Vendors Establish Establish Qualify Qualified Qualified
BOM = Bill of Materials OCAP = Out of Control Action Plan
Gating Requirments
Responsibility Requirement Concept Prototype Pilot Production
Engineer Application Review Preliminary Finalized Review Review
Engineer / MarketingReview of competitive landscape.Is it favorable?
Finalized
EngineerProduct History (new product, derivative, cost reduction, change)
Finalized
Eng / Sales / Marketing / Purchaseing
Design to Cost Goals Preliminary FinalizedAdjust /Revise
Adjust /Revise
EngineerIntellectual Property / Patent Review
Finalized Review Review Review
Engineer / Patent Attorney
Intellectual Property Creation / Patent Disclosure Submitted
Review Finalized Review Review
Sales / PM / EngineerCustomer Schedule /Milestones Defined
Preliminary Finalized Review Review
Engineer Detailed Review of Product Design
Preliminary Finalized Review
EngineerReview of analysis completed to validate design
Preliminary Finalized Review
EngineerReview for compliance to existing engineering specifications
Preliminary Finalized Review Review
Engineer DFMEA Completion and Review Preliminary Finalized Review Review
Sales / PM / Engineer Customer Specification Review Preliminary FinalizedReview / Adjust
Review
EngineerDesign and Production Validation Test Plans
Preliminary Finalized Review
EngineerReview of Design and Production Validations Completed
PreliminaryDesign
FinalizedPilot
FinalizedProduction Finalized
Engineers(design, proc and equip)
Prototype and Production Tooling / Equipment Strategies
PreliminaryDesign
FinalizedProduction Finalized
Purchasing / Engineer Supplier Reviews Preliminary FinalizedPM / Engineer Risk Assessment Preliminary Finalized Review Review
PM / Engineer Lessons LearnedPrevious Products
Review Review Finalized
PM - Program Manager
Design Review Gating Requirments
CONFIDENTIAL Process Relations GmbH
Slide 24
Benefits of the usage MIG TDP Template
CONFIDENTIAL Process Relations GmbH
Slide 25
But Technology vs. Product Development
COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff
The next level – CORONA Methodology
CONFIDENTIAL Process Relations GmbH
Slide 27
To be provoking …
CONFIDENTIAL Process Relations GmbH
Slide 28
… with Customer Involvement
The customer is the one who has detailed product knowledge Methodology must reflect customer interaction
Customer-DrivenProduct
Engineering
Customer:Define requirements and constraints, initiate, supervise and control product realization
Spec
ifica
tion,
Con
trol
ling
Assessm
ent
Sign-Off
Implementation,
Verification
DevelopmentTurns idea into technically feasible product description guided by customer
ManufacturingProduce device fromproduct description to meetcustomer needs
CONFIDENTIAL Process Relations GmbH
Slide 29
… with Customer Involvement
The customer is the one who has detailed product knowledge Methodology must reflect customer interaction
Customer-DrivenProduct
Engineering
Customer:Define requirements and constraints, initiate, supervise and control product realization
Result ValidationProduce or result assessment“to do things right”
Spec
ifica
tion,
Con
trol
ling
Assessm
ent
Sign-Off
Implementation,
Verification
Task DefinitionProduct descriptionguided by customer control“to do the right things”
CONFIDENTIAL Process Relations GmbH
Slide 30
Product Engineering – Overview
Project ManagementPRINCE2
Product DevelopmentStage Gate™
CONFIDENTIAL Process Relations GmbH
Slide 31
Benefits from MEMS PE
Shorter time-to-market: Reduced cycle time Fewer learning cycles
Access to knowledge-bases on design and fabrication ICT based structure
and tools Improved transfer of knowledge from design to production
Customer-lead multi-site product development
100 % product level
time
3rd 2nd 1st cycle
MEMS PE enables reduced development times, shorter cycles reduced time to market
CONFIDENTIAL Process Relations GmbH
Slide 32
Documentation of this approach
TO BE PUBLISHED
OCTOBER 2013
COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff
Conclusions
CONFIDENTIAL Process Relations GmbH
Slide 34
Collaboration between Design and Process 2.0
Microlelectronics:Clear separation between manufacturing and application development
Micro Nano Technology: „closing the loop“
Concept Behaviour FabricationStructure Geometry
De
sig
n R
ule
s
Concept Behaviour FabricationStructure Geometry
CONFIDENTIAL Process Relations GmbH
Slide 35
MEMS development collaboration challenges can be overcome by Putting the customer in control
Following a customer driven, thorough collaboration methodology
Adopting documented best practices
Pursue new approaches of data exchange and infrastructure