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LEAN Implementation @Global company
May 11, 2015
Carmit Berdugo Cohen – Quality Manager, KT Israel
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KLA-Tencor – Who Are We?
KLA-Tencor supports the semiconductor industry with advanced inspection & metrology process control solutions.
Our cutting-edge hardware and software technology identifies defects in semiconductor chip manufacturing.
We help assure that everything from MP3 players and plasma HDTV's to PCs, Macs and iPhones work with precision.
You almost certainly own a product with a chip that our technology made FASTER, SMALLER & SMARTER.
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We’re Not Just in Silicon Valley…
North America United States25%
Europe U.K.FranceGermanyIreland15%
ScotlandNetherlandsItalySpain Middle East
Israel
South Asia India
Asia Pacific Japan – 20%KoreaTaiwanSingapore 40%MalaysiaChina
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Global Leader in Yield Acceleration Since 1976
Installed base ~25,000 tools
>5,110 employees
>3,264 technical personnel in 17 countries
>$1.5B R&D investments over last 4 years
FY 2010 revenue: >$1.8B+
Customers: Intel
IBM
Samsung
Motorola
AMDR&D expenditures
3x that of our combined top 3 competitors
Competitors
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KLA-Tencor’s Technology Impacts YOU
MP3 Players Plasma HDTV Satellite TV
DVR
DigitalSLR
Portable DVD
Cell Phone
PCs & Macs
Car DVD
DigitalCamera
NR Headphones
Navigation
System
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19901980 2000 today
0.065m
1.5m
1m
0.5m
0.35m
0.25m
0.18m
0.13m
0.09m
Se
mic
on
du
cto
r D
esi
gn
R
ule
s
• Faster
• Cheaper
• Smaller
More materials lead to more defect types: More process control needed
Consumer Era–Short Product Lifetimes (Cell Phone Evolution)
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Define “Small”
Our Tools Will Find a Defect the Size of a Small Coin on the Great Wall of China…in Seconds
One Chip
WaferThe Great Wall of China
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Honey, I Shrunk the Substrate
Source: KLA-Tencor
0.01 micron (10nm)DNA Strand Diameter: ~6nm
0.1 micron (100nm)Semiconductor Bridging Defect: ~30nm
1 nanometer (nm)
1 mm (1,000,000nm)Human Hair: ~100,000nm
1 cm (10,000,000nm)Head of a Pin: ~2,000,000nm
0.1 mm (100,000nm)Red Blood Cell: ~5,000nm
1 micron (1,000nm)Bacteria: ~800nm
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Obstacles To Improving Yield
0.01 micron (10nm)DNA Strand Diameter: ~6nm
0.1 micron (100nm)Semiconductor Bridging Defect: ~30nm
1 nanometer (nm)
1 mm (1,000,000nm)Human Hair: ~100,000nm
1 cm (10,000,000nm)Head of a Pin: ~2,000,000nm
0.1 mm (100,000nm)Red Blood Cell: ~5,000nm
1 micron (1,000nm)Bacteria: ~800nm
Source: KLA-Tencor
KLA-Tencor Provides Systems that Enable Finding Defects and Measuring Critical Dimensions
And…You can’t control what you can’t measure!
You can’t fix what you can’t find!
Smaller Overlay Window
(yield & reliability challenges)
Source Drain
Transistor
GateDielectric
35 nm GateLength
METROLOGY
DefectiveVia
BARCUnder-Etch
Void
Buried void
Residual Polymer
Poisoned Resist
Chamber Flake
High Aspect
Ratio Defect
DEFECTS
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Why LEAN
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הצורך בניהול רזה
שינוי בקצב השינוי
Current population 6,9 billion
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12 KLA-Tencor Confidential - Internal Use Only
שינוי בקצב השינוי - מאקרו
משמעומשמעותת
שינוייםשינויים
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עלויות ייצור גבוהות
שינוי במס' המכונות המוזמנות
Build Planשינויים גדולים בתחזית
תהליכים לא עקביים
חוסרים בחומרים
Up/Down turnריבוי ב-
שינוי בקצב השינוי - מיקרו
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14 KLA-Tencor Confidential - Internal Use Only
של כל יתרון תחרותי ארגונית ליצירת אסטרטגיה
ארגון
התחרות ע"י: כושרשיפור
קיצור זמני תגובה
שיפור באיכות המוצר/השרות
הורדת עלויות
גישות לחיסול הבזבוז עם כלים טכניים שילוב של
רכות
תפישת "הניהול הרזה"
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מירבי ללקוחערךהפעלת הארגון להענקת
בתהליך: גורמים חסרי ערך ללקוחבזבזניםצמצום
בחינת התהליך דרך משקפי הלקוח
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16 KLA-Tencor Confidential - Internal Use Only
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Global Infrastructure
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Building LEAN Teams
GOPS Steering Committee
LEAN Owners
LEAN Owners
LEAN Owners
LEAN Owners
LEAN Owners
Israel USA Singapore Germany Hong Kong
EXPERTEAM
Zone Leaders
EXPERTEAM
Zone Leaders
EXPERTEAM
Zone Leaders
EXPERTEAM
Zone Leaders
EXPERTEAM
Zone Leaders
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Adding LEAN to GOPS BSC
Productivity ($) Adoption (Score) Inventory Turns
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Building the Infrastructure
LEAN Maturity Model (LMM)
Cost Saving Model
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What is LMM?
Diagnostic tool to assess Lean progress
Feedback system to measure effects (and respond accordingly)
Cross-Site Lean Summit (Gemba Visit)
Common Language
Common Framework: Standards, BKMs
Promote Cross-Site interaction
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Lean Maturity Model Assessment
To achieve the World Class Manufacturing, focus is on 22 key characteristics, which are grouped into the 7 categories
In general the scoring (1 to 5) is aligned similar to guidelines shown below
1 2 3 4 5
Basic understanding or implementation beginning to occur.
Active programs/projects to develop understanding of the category, perhaps some implementation by the management team is expected.
Active programs/projects to develop understanding of the category, with implementation being actively driven by the management team and deeper into several parts of the organization.
Thorough understanding and implementation throughout the organization.
Thorough understanding and implementation throughout the extended value stream, from supplier through the organization to the customer.
Assessment Category Total5S 2Continuous Improvement 4Culture 2Measurement & Matrix 4Mgmt Support 3Quality 2LEAN tools 5Grand Total 22
Complete LMM score sheet
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Assessment Tool – Lean Maturity – Example
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Assessment Tool – Lean Maturity – Example
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Assessment Tool – Lean Maturity – Example
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Building the Infrastructure
LEAN Maturity Model (LMM)
Cost Saving Model
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Productivity Lean Savings – Guidelines
“Lean” Savings – savings captured from:
Projects specifically identified / driven by Lean Initiative activity
Includes Projects, routine cell 5S, Kaizen & Red Tag Event activity
*
*
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Example for Savings - KTI
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Reporting Performance Qtrly
Productivity ($) Adoption (Score) Inventory Turns
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Thank You